Ford - Explorer 2wd - Workshop Manual - 2001 - 2001

Factory Workshop Manual Make Ford Model Explorer 2wd Engine and year V6-245 4.0L SOHC VIN K SFI (2001) 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0100 - P0104, ( P0101 P0102 P0103 0100 0101 0102 0103 0104 ) > System Information > System Diagnosis > P0102 P0100 - P0104: Testing and Inspection P0102 For diagnosis of code P0102 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0100 - P0104, ( P0101 P0102 P0103 0100 0101 0102 0103 0104 ) > System Information > System Diagnosis > P0102 > Page 9 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0100 - P0104, ( P0101 P0102 P0103 0100 0101 0102 0103 0104 ) > System Information > System Diagnosis > P0102 > Page 10 P0100 - P0104: Testing and Inspection P0103 For diagnosis of code P0103 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0100 - P0104, ( P0101 P0102 P0103 0100 0101 0102 0103 0104 ) > System Information > System Diagnosis > P0102 > Page 11 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 P0105 - P0109: Testing and Inspection P0106 For diagnosis of code P0106 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 16 For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 17 P0105 - P0109: Testing and Inspection P0107 For diagnosis of code P0107 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 18 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 19 P0105 - P0109: Testing and Inspection P0108 For diagnosis of code P0108 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 20 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 21 P0105 - P0109: Testing and Inspection P0109 For diagnosis of code P0109 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 22 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114, ( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis > P0112 P0110 - P0114: Testing and Inspection P0112 For diagnosis of code P0112 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114, ( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis > P0112 > Page 27 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114, ( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis > P0112 > Page 28 P0110 - P0114: Testing and Inspection P0113 For diagnosis of code P0113 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114, ( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis > P0112 > Page 29 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119, ( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 P0115 - P0119: Testing and Inspection P0116 For diagnosis of code P0116 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119, ( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 34 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119, ( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 35 P0115 - P0119: Testing and Inspection P0117 For diagnosis of code P0117 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119, ( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 36 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119, ( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 37 P0115 - P0119: Testing and Inspection P0118 For diagnosis of code P0118 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119, ( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 38 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 P0120 - P0124: Testing and Inspection P0121 For diagnosis of code P0121 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 43 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 44 P0120 - P0124: Testing and Inspection P0122 For diagnosis of code P0122 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 45 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 46 P0120 - P0124: Testing and Inspection P0123 For diagnosis of code P0123 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 47 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0125 - P0129, ( P0126 P0127 P0128 0125 0126 0127 0128 0129 ) > System Information > System Diagnosis > P0125 P0125 - P0129: Testing and Inspection P0125 For diagnosis of code P0125 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0125 - P0129, ( P0126 P0127 P0128 0125 0126 0127 0128 0129 ) > System Information > System Diagnosis > P0125 > Page 52 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0125 - P0129, ( P0126 P0127 P0128 0125 0126 0127 0128 0129 ) > System Information > System Diagnosis > P0125 > Page 53 P0125 - P0129: Testing and Inspection P0127 For diagnosis of code P0127 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0125 - P0129, ( P0126 P0127 P0128 0125 0126 0127 0128 0129 ) > System Information > System Diagnosis > P0125 > Page 54 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134, ( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0131 P0130 - P0134: Testing and Inspection P0131 For diagnosis of code P0131 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134, ( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0131 > Page 59 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134, ( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0131 > Page 60 P0130 - P0134: Testing and Inspection P0133 For diagnosis of code P0133 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134, ( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0131 > Page 61 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139, ( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135 P0135 - P0139: Testing and Inspection P0135 For diagnosis of code P0135 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139, ( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135 > Page 66 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139, ( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135 > Page 67 P0135 - P0139: Testing and Inspection P0136 For diagnosis of code P0136 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139, ( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135 > Page 68 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0140 - P0144, ( P0141 P0142 P0143 0140 0141 0142 0143 0144 ) > System Information > System Diagnosis P0140 - P0144: Testing and Inspection For diagnosis of code P0141 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0140 - P0144, ( P0141 P0142 P0143 0140 0141 0142 0143 0144 ) > System Information > System Diagnosis > Page 72 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0145 - P0149, ( P0146 P0127 P0148 0145 0146 0147 0148 0149 ) > System Information > System Diagnosis P0145 - P0149: Testing and Inspection For diagnosis of code P0148 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0145 - P0149, ( P0146 P0127 P0148 0145 0146 0147 0148 0149 ) > System Information > System Diagnosis > Page 76 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154, ( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0151 P0150 - P0154: Testing and Inspection P0151 For diagnosis of code P0151 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154, ( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0151 > Page 81 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154, ( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0151 > Page 82 P0150 - P0154: Testing and Inspection P0153 For diagnosis of code P0153 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154, ( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0151 > Page 83 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159, ( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155 P0155 - P0159: Testing and Inspection P0155 For diagnosis of code P0155 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159, ( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155 > Page 88 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159, ( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155 > Page 89 P0155 - P0159: Testing and Inspection P0156 For diagnosis of code P0156 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159, ( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155 > Page 90 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0160 - P0164, ( P0161 P0162 P0163 0160 0161 0162 0163 0164 ) > System Information > System Diagnosis P0160 - P0164: Testing and Inspection For diagnosis of code P0161 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0160 - P0164, ( P0161 P0162 P0163 0160 0161 0162 0163 0164 ) > System Information > System Diagnosis > Page 94 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 P0170 - P0174: Testing and Inspection P0171 For diagnosis of code P0171 refer to chart Bxxxx, Cxxxx, P0102 - P0171 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 99 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 100 P0170 - P0174: Testing and Inspection P0172 For diagnosis of code P0172 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 101 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 102 P0170 - P0174: Testing and Inspection P0174 For diagnosis of code P0174 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 103 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0175 - P0179, ( P0176 P0177 P0178 0175 0176 0177 0178 0179 ) > System Information > System Diagnosis > P0175 P0175 - P0179: Testing and Inspection P0175 For diagnosis of code P0175 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0175 - P0179, ( P0176 P0177 P0178 0175 0176 0177 0178 0179 ) > System Information > System Diagnosis > P0175 > Page 108 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0175 - P0179, ( P0176 P0177 P0178 0175 0176 0177 0178 0179 ) > System Information > System Diagnosis > P0175 > Page 109 P0175 - P0179: Testing and Inspection P0176 For diagnosis of code P0176 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0175 - P0179, ( P0176 P0177 P0178 0175 0176 0177 0178 0179 ) > System Information > System Diagnosis > P0175 > Page 110 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 P0180 - P0184: Testing and Inspection P0180 For diagnosis of code P0180 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 115 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 116 P0180 - P0184: Testing and Inspection P0181 For diagnosis of code P0181 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 117 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 118 P0180 - P0184: Testing and Inspection P0182 For diagnosis of code P0182 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 119 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 120 P0180 - P0184: Testing and Inspection P0183 For diagnosis of code P0183 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 121 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 P0190 - P0194: Testing and Inspection P0190 For diagnosis of code P0190 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 126 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 127 P0190 - P0194: Testing and Inspection P0191 For diagnosis of code P0191 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 128 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 129 P0190 - P0194: Testing and Inspection P0192 For diagnosis of code P0192 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 130 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 131 P0190 - P0194: Testing and Inspection P0193 For diagnosis of code P0193 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 132 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 P0200 - P0204: Testing and Inspection P0201 For diagnosis of code P0201 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 138 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 139 P0200 - P0204: Testing and Inspection P0202 For diagnosis of code P0202 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 140 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 141 P0200 - P0204: Testing and Inspection P0203 For diagnosis of code P0203 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 142 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 143 P0200 - P0204: Testing and Inspection P0204 For diagnosis of code P0204 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 144 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 P0205 - P0209: Testing and Inspection P0205 For diagnosis of code P0205 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 149 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 150 P0205 - P0209: Testing and Inspection P0206 For diagnosis of code P0206 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 151 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 152 P0205 - P0209: Testing and Inspection P0207 For diagnosis of code P0207 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 153 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 154 P0205 - P0209: Testing and Inspection P0208 For diagnosis of code P0208 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 155 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 156 P0205 - P0209: Testing and Inspection P0209 For diagnosis of code P0209 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 157 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214, ( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 P0210 - P0214: Testing and Inspection P0210 For diagnosis of code P0210 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214, ( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 162 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214, ( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 163 P0210 - P0214: Testing and Inspection P0211 For diagnosis of code P0211 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214, ( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 164 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214, ( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 165 P0210 - P0214: Testing and Inspection P0212 For diagnosis of code P0212 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214, ( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 166 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0215 - P0219, ( P0216 P0217 P0218 0215 0216 0217 0218 0219 ) > System Information > System Diagnosis P0215 - P0219: Testing and Inspection For diagnosis of code P0217 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0215 - P0219, ( P0216 P0217 P0218 0215 0216 0217 0218 0219 ) > System Information > System Diagnosis > Page 170 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 P0230 - P0234: Testing and Inspection P0230 For diagnosis of code P0230 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 175 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 176 P0230 - P0234: Testing and Inspection P0231 For diagnosis of code P0231 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 177 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 178 P0230 - P0234: Testing and Inspection P0232 For diagnosis of code P0232 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 179 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 180 P0230 - P0234: Testing and Inspection P0234 For diagnosis of code P0234 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 181 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0240 - P0244, ( P0241 P0242 P0243 0240 0241 0242 0243 0244 ) > System Information > System Diagnosis P0240 - P0244: Testing and Inspection For diagnosis of code P0243 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0240 - P0244, ( P0241 P0242 P0243 0240 0241 0242 0243 0244 ) > System Information > System Diagnosis > Page 185 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0295 - P0299, ( P0296 P0297 P0298 0295 0296 0297 0298 0299 ) > System Information > System Diagnosis P0295 - P0299: Testing and Inspection For diagnosis of code P0298 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0295 - P0299, ( P0296 P0297 P0298 0295 0296 0297 0298 0299 ) > System Information > System Diagnosis > Page 189 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 P0300 - P0304: Testing and Inspection P0300 For diagnosis of code P0300 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 195 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 196 P0300 - P0304: Testing and Inspection P0301 For diagnosis of code P0301 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 197 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 198 P0300 - P0304: Testing and Inspection P0302 For diagnosis of code P0302 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 199 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 200 P0300 - P0304: Testing and Inspection P0303 For diagnosis of code P0303 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 201 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 202 P0300 - P0304: Testing and Inspection P0304 For diagnosis of code P0304 refer to chart P0172 - P0304 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 203 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 P0305 - P0309: Testing and Inspection P0305 For diagnosis of code P0305 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 208 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 209 P0305 - P0309: Testing and Inspection P0306 For diagnosis of code P0306 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 210 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 211 P0305 - P0309: Testing and Inspection P0307 For diagnosis of code P0307 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 212 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 213 P0305 - P0309: Testing and Inspection P0308 For diagnosis of code P0308 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 214 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 215 P0305 - P0309: Testing and Inspection P0309 For diagnosis of code P0309 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 216 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0310 - P0314, ( P0311 P0312 P0313 0310 0311 0312 0313 0314 ) > System Information > System Diagnosis P0310 - P0314: Testing and Inspection For diagnosis of code P0310 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0310 - P0314, ( P0311 P0312 P0313 0310 0311 0312 0313 0314 ) > System Information > System Diagnosis > Page 220 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0320 - P0324, ( P0321 P0322 P0323 0320 0321 0322 0323 0324 ) > System Information > System Diagnosis P0320 - P0324: Testing and Inspection For diagnosis of code P0320 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0320 - P0324, ( P0321 P0322 P0323 0320 0321 0322 0323 0324 ) > System Information > System Diagnosis > Page 224 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329, ( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325 P0325 - P0329: Testing and Inspection P0325 For diagnosis of code P0325 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329, ( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325 > Page 229 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329, ( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325 > Page 230 P0325 - P0329: Testing and Inspection P0326 For diagnosis of code P0326 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329, ( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325 > Page 231 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0330 - P0334, ( P0331 P0332 P0333 0330 0331 0332 0333 0334 ) > System Information > System Diagnosis > P0330 P0330 - P0334: Testing and Inspection P0330 For diagnosis of code P0330 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0330 - P0334, ( P0331 P0332 P0333 0330 0331 0332 0333 0334 ) > System Information > System Diagnosis > P0330 > Page 236 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0330 - P0334, ( P0331 P0332 P0333 0330 0331 0332 0333 0334 ) > System Information > System Diagnosis > P0330 > Page 237 P0330 - P0334: Testing and Inspection P0331 For diagnosis of code P0331 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0330 - P0334, ( P0331 P0332 P0333 0330 0331 0332 0333 0334 ) > System Information > System Diagnosis > P0330 > Page 238 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0340 - P0344, ( P0341 P0342 P0343 0340 0341 0342 0343 0344 ) > System Information > System Diagnosis P0340 - P0344: Testing and Inspection For diagnosis of code P0340 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0340 - P0344, ( P0341 P0342 P0343 0340 0341 0342 0343 0344 ) > System Information > System Diagnosis > Page 242 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 P0350 - P0354: Testing and Inspection P0350 For diagnosis of code P0350 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 247 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 248 P0350 - P0354: Testing and Inspection P0351 For diagnosis of code P0351 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 249 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 250 P0350 - P0354: Testing and Inspection P0352 For diagnosis of code P0352 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 251 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 252 P0350 - P0354: Testing and Inspection P0353 For diagnosis of code P0353 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 253 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 254 P0350 - P0354: Testing and Inspection P0354 For diagnosis of code P0354 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 255 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 P0355 - P0359: Testing and Inspection P0355 For diagnosis of code P0355 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 260 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 261 P0355 - P0359: Testing and Inspection P0356 For diagnosis of code P0356 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 262 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 263 P0355 - P0359: Testing and Inspection P0357 For diagnosis of code P0357 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 264 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 265 P0355 - P0359: Testing and Inspection P0358 For diagnosis of code P0358 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 266 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 267 P0355 - P0359: Testing and Inspection P0359 For diagnosis of code P0359 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 268 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0360 - P0364, ( P0361 P0362 P0363 0360 0361 0362 0363 0364 ) > System Information > System Diagnosis P0360 - P0364: Testing and Inspection For diagnosis of code P0360 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0360 - P0364, ( P0361 P0362 P0363 0360 0361 0362 0363 0364 ) > System Information > System Diagnosis > Page 272 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 P0400 - P0404: Testing and Inspection P0400 For diagnosis of code P0400 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 278 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 279 P0400 - P0404: Testing and Inspection P0401 For diagnosis of code P0401 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 280 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 281 P0400 - P0404: Testing and Inspection P0402 For diagnosis of code P0402 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 282 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 283 P0400 - P0404: Testing and Inspection P0403 For diagnosis of code P0403 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 284 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0410 - P0414, ( P0411 P0412 P0413 0410 0411 0412 0413 0414 ) > System Information > System Diagnosis > P0411 P0410 - P0414: Testing and Inspection P0411 For diagnosis of code P0411 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0410 - P0414, ( P0411 P0412 P0413 0410 0411 0412 0413 0414 ) > System Information > System Diagnosis > P0411 > Page 289 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0410 - P0414, ( P0411 P0412 P0413 0410 0411 0412 0413 0414 ) > System Information > System Diagnosis > P0411 > Page 290 P0410 - P0414: Testing and Inspection P0412 For diagnosis of code P0412 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0410 - P0414, ( P0411 P0412 P0413 0410 0411 0412 0413 0414 ) > System Information > System Diagnosis > P0411 > Page 291 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0420 - P0424, ( P0421 P0422 P0423 0420 0421 0422 0423 0424 ) > System Information > System Diagnosis P0420 - P0424: Testing and Inspection For diagnosis of code P0420 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0420 - P0424, ( P0421 P0422 P0423 0420 0421 0422 0423 0424 ) > System Information > System Diagnosis > Page 295 For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0430 - P0434, ( P0431 P0432 P0433 0430 0431 0432 0433 0434 ) > System Information > System Diagnosis P0430 - P0434: Testing and Inspection For diagnosis of code P0430 refer to chart P0305 - P0442 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0430 - P0434, ( P0431 P0432 P0433 0430 0431 0432 0433 0434 ) > System Information > System Diagnosis > Page 299 For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0440 - P0444, ( P0441 P0442 P0443 0440 0441 0442 0443 0444 ) > System Information > System Diagnosis > P0442 P0440 - P0444: Testing and Inspection P0442 For diagnosis of code P0442 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information , See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0440 - P0444, ( P0441 P0442 P0443 0440 0441 0442 0443 0444 ) > System Information > System Diagnosis > P0442 > Page 304 P0440 - P0444: Testing and Inspection P0443 For diagnosis of code P0443 refer to chart P0443 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0440 - P0444, ( P0441 P0442 P0443 0440 0441 0442 0443 0444 ) > System Information > System Diagnosis > P0442 > Page 305 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 P0450 - P0454: Testing and Inspection P0451 For diagnosis of code P0451 refer to chart P0443 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 310 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 311 P0450 - P0454: Testing and Inspection P0452 For diagnosis of code P0452 refer to chart P0443 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 312 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 313 P0450 - P0454: Testing and Inspection P0453 For diagnosis of code P0453 refer to chart P0443 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 314 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0455 - P0459, ( P0456 P0457 P0458 0455 0456 0457 0458 0459 ) > System Information > System Diagnosis > P0455 P0455 - P0459: Testing and Inspection P0455 For diagnosis of code P0455 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information , See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0455 - P0459, ( P0456 P0457 P0458 0455 0456 0457 0458 0459 ) > System Information > System Diagnosis > P0455 > Page 319 P0455 - P0459: Testing and Inspection P0457 For diagnosis of code P0457 refer to chart P0443 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0455 - P0459, ( P0456 P0457 P0458 0455 0456 0457 0458 0459 ) > System Information > System Diagnosis > P0455 > Page 320 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464, ( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 P0460 - P0464: Testing and Inspection P0460 For diagnosis of code P0460 refer to chart P0443 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464, ( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 > Page 325 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464, ( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 > Page 326 P0460 - P0464: Testing and Inspection P0461 For diagnosis of code P0461 refer to chart P0443 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464, ( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 > Page 327 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 P0500 - P0504: Testing and Inspection P0500 For diagnosis of P0500 refer to system experiencing problems. Engine Control System or Transmission Control System P0443 - P071x Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 333 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control System diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Wiper and Washer Systems Part 1 Of 5 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Wiper and Washer system diagnostic information, See: Wiper and Washer Systems/Testing and Inspection Transfer Case Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 334 B2141-B2106 / P1763-P1826 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 335 P0500 - P0504: Testing and Inspection P0501 For diagnosis of code P0501 refer to chart P0443 - P071x NOTE 12: Vehicle Speed information is provided by the Antilock Brake System (ABS). Perform complete diagnosis, See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 336 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 337 P0500 - P0504: Testing and Inspection P0503 For diagnosis of code P0503 refer to chart P0443 - P071x NOTE 12: Vehicle Speed information is provided by the Antilock Brake System (ABS). Perform complete diagnosis, See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 338 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0505 - P0509, ( P0506 P0507 P0508 0505 0506 0507 0508 0509 ) > System Information > System Diagnosis P0505 - P0509: Testing and Inspection For diagnosis of code P0505 refer to chart P0443 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0505 - P0509, ( P0506 P0507 P0508 0505 0506 0507 0508 0509 ) > System Information > System Diagnosis > Page 342 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0550 - P0554, ( P0551 P0552 P0553 0550 0551 0552 0553 0554 ) > System Information > System Diagnosis > P0552 P0550 - P0554: Testing and Inspection P0552 For diagnosis of code P0552 refer to chart P0443 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0550 - P0554, ( P0551 P0552 P0553 0550 0551 0552 0553 0554 ) > System Information > System Diagnosis > P0552 > Page 347 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0550 - P0554, ( P0551 P0552 P0553 0550 0551 0552 0553 0554 ) > System Information > System Diagnosis > P0552 > Page 348 P0550 - P0554: Testing and Inspection P0553 For diagnosis of code P0553 refer to chart P0443 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0550 - P0554, ( P0551 P0552 P0553 0550 0551 0552 0553 0554 ) > System Information > System Diagnosis > P0552 > Page 349 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604, ( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0602 P0600 - P0604: Testing and Inspection P0602 For diagnosis of code P0602 refer to chart P0443 - P071x NOTE 11: The vehicle ID block (VID) needs to be reprogrammed. Refer to VID Block Procedure. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604, ( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0602 > Page 355 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604, ( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0602 > Page 356 P0600 - P0604: Testing and Inspection P0603 For diagnosis of code P0603 refer to chart P0443 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604, ( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0602 > Page 357 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0605 - P0609, ( P0606 P0607 P0608 0605 0606 0607 0608 0609 ) > System Information > System Diagnosis P0605 - P0609: Testing and Inspection For diagnosis of code P0605 refer to chart P0443 - P071x NOTE 14: Be sure to check for aftermarket performance products before replacing PCM. If replacement is necessary refer to Flash Electrically Erasable Programmable Read Only Memory (EEPROM), See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0605 - P0609, ( P0606 P0607 P0608 0605 0606 0607 0608 0609 ) > System Information > System Diagnosis > Page 361 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0700 - P0704, ( P0701 P0702 P0703 0700 0701 0702 0703 0704 ) > System Information > System Diagnosis > P0703 P0700 - P0704: Testing and Inspection P0703 For diagnosis of code P0703 refer to chart P0443 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0700 - P0704, ( P0701 P0702 P0703 0700 0701 0702 0703 0704 ) > System Information > System Diagnosis > P0703 > Page 367 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0700 - P0704, ( P0701 P0702 P0703 0700 0701 0702 0703 0704 ) > System Information > System Diagnosis > P0703 > Page 368 P0700 - P0704: Testing and Inspection P0704 For diagnosis of code P0704 refer to chart P0443 - P071x If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0700 - P0704, ( P0701 P0702 P0703 0700 0701 0702 0703 0704 ) > System Information > System Diagnosis > P0703 > Page 369 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 P0705 - P0709: Testing and Inspection P0705 For diagnosis of code P0705 refer to chart P0705-P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 374 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 375 P0705 - P0709: Testing and Inspection P0708 For diagnosis of code P0708 refer to chart P0705-P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 376 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 P0710 - P0714: Testing and Inspection P0712 For diagnosis of code P0712 refer to chart P0712-P1780 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 > Page 381 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 > Page 382 P0710 - P0714: Testing and Inspection P0713 For diagnosis of code P0713 refer to chart P0712-P1780 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 > Page 383 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0715 - P0719, ( P0716 P0717 P0718 0715 0716 0717 0718 0719 ) > System Information > System Diagnosis P0715 - P0719: Testing and Inspection For diagnosis of code P0715 refer to chart P0712-P1780 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0715 - P0719, ( P0716 P0717 P0718 0715 0716 0717 0718 0719 ) > System Information > System Diagnosis > Page 387 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission P0720 - P0724: Testing and Inspection Manual Transmission For diagnosis of code P072x refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission > Page 392 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Note: "x" = any number 0 thru 9 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission > Page 393 P0720 - P0724: Testing and Inspection Automatic Transmission P0720 For diagnosis of code P0720 refer to chart P0720-P1740 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission > Page 394 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection P0721 For diagnosis of code P0721 refer to chart Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission > Page 395 P0720-P1740 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission > Page 396 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0725 - P0729, ( P0726 P0727 P0728 0725 0726 0727 0728 0729 ) > System Information > System Diagnosis P0725 - P0729: Testing and Inspection For diagnosis of code P072x refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0725 - P0729, ( P0726 P0727 P0728 0725 0726 0727 0728 0729 ) > System Information > System Diagnosis > Page 400 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Note: "x" = any number 0 thru 9 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 P0730 - P0734: Testing and Inspection P0731 For diagnosis of code P0731 refer to chart P0731-P1703 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 405 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 406 P0730 - P0734: Testing and Inspection P0732 For diagnosis of code P0732 refer to chart P0731-P1703 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 407 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 408 P0730 - P0734: Testing and Inspection P0733 For diagnosis of code P0733 refer to chart P0733-P0755 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 409 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 410 P0730 - P0734: Testing and Inspection P0734 For diagnosis of code P0734 refer to chart P0733-P0755 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734, ( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 411 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0735 - P0739, ( P0736 P0737 P0738 0735 0736 0737 0738 0739 ) > System Information > System Diagnosis P0735 - P0739: Testing and Inspection For diagnosis of code P0735 refer to chart P0720-P1740 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0735 - P0739, ( P0736 P0737 P0738 0735 0736 0737 0738 0739 ) > System Information > System Diagnosis > Page 415 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741 P0740 - P0744: Testing and Inspection P0741 For diagnosis of code P0741 refer to chart P0712-P1780 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741 > Page 420 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741 > Page 421 P0740 - P0744: Testing and Inspection P0743 For diagnosis of code P0743 refer to chart P0712-P1780 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741 > Page 422 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0750 - P0754, ( P0751 P0752 P0753 0750 0751 0752 0753 0754 ) > System Information > System Diagnosis P0750 - P0754: Testing and Inspection For diagnosis of code P0750 refer to chart P0733-P0755 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0750 - P0754, ( P0751 P0752 P0753 0750 0751 0752 0753 0754 ) > System Information > System Diagnosis > Page 426 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0755 - P0759, ( P0756 P0757 P0758 0755 0756 0757 0758 0759 ) > System Information > System Diagnosis P0755 - P0759: Testing and Inspection For diagnosis of code P0755 refer to chart P0733-P0755 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0755 - P0759, ( P0756 P0757 P0758 0755 0756 0757 0758 0759 ) > System Information > System Diagnosis > Page 430 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0760 - P0764, ( P0761 P0762 P0763 0760 0761 0762 0763 0764 ) > System Information > System Diagnosis P0760 - P0764: Testing and Inspection For diagnosis of code P0760 refer to chart P0705-P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0760 - P0764, ( P0761 P0762 P0763 0760 0761 0762 0763 0764 ) > System Information > System Diagnosis > Page 434 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0765 - P0769, ( P0766 P0767 P0768 0765 0766 0767 0768 0769 ) > System Information > System Diagnosis P0765 - P0769: Testing and Inspection For diagnosis of code P0765 refer to chart P0720-P1740 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0765 - P0769, ( P0766 P0767 P0768 0765 0766 0767 0768 0769 ) > System Information > System Diagnosis > Page 438 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0800-P08ZZ > P0810 - P0814, ( P0811 P0812 P0813 0810 0811 0812 0813 0814 ) > System Information > System Diagnosis P0810 - P0814: Testing and Inspection For diagnosis of code P0812 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0800-P08ZZ > P0810 - P0814, ( P0811 P0812 P0813 0810 0811 0812 0813 0814 ) > System Information > System Diagnosis > Page 443 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1000-P10ZZ > P1000 - P1004, ( P1001 P1002 P1003 1000 1001 1002 1003 1004 ) > System Information > System Diagnosis > P1000 P1000 - P1004: Testing and Inspection P1000 For diagnosis of code P1000 refer to chart P072x - P1138 NOTE 1: DTC P1000 is ignored in KOEO and KOER Self-Test. Disregard the DTC P1000 and continue as directed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1000-P10ZZ > P1000 - P1004, ( P1001 P1002 P1003 1000 1001 1002 1003 1004 ) > System Information > System Diagnosis > P1000 > Page 449 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1000-P10ZZ > P1000 - P1004, ( P1001 P1002 P1003 1000 1001 1002 1003 1004 ) > System Information > System Diagnosis > P1000 > Page 450 P1000 - P1004: Testing and Inspection P1001 For diagnosis of code P1001 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1000-P10ZZ > P1000 - P1004, ( P1001 P1002 P1003 1000 1001 1002 1003 1004 ) > System Information > System Diagnosis > P1000 > Page 451 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1100 - P1104, ( P1101 P1102 P1103 1100 1101 1102 1103 1104 ) > System Information > System Diagnosis > P1100 P1100 - P1104: Testing and Inspection P1100 For diagnosis of code P1100 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1100 - P1104, ( P1101 P1102 P1103 1100 1101 1102 1103 1104 ) > System Information > System Diagnosis > P1100 > Page 457 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1100 - P1104, ( P1101 P1102 P1103 1100 1101 1102 1103 1104 ) > System Information > System Diagnosis > P1100 > Page 458 P1100 - P1104: Testing and Inspection P1101 For diagnosis of code P1101 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1100 - P1104, ( P1101 P1102 P1103 1100 1101 1102 1103 1104 ) > System Information > System Diagnosis > P1100 > Page 459 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1110 - P1114, ( P1111 P1112 P1113 1110 1111 1112 1113 1114 ) > System Information > System Diagnosis > P1112 P1110 - P1114: Testing and Inspection P1112 For diagnosis of code P1112 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1110 - P1114, ( P1111 P1112 P1113 1110 1111 1112 1113 1114 ) > System Information > System Diagnosis > P1112 > Page 464 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1110 - P1114, ( P1111 P1112 P1113 1110 1111 1112 1113 1114 ) > System Information > System Diagnosis > P1112 > Page 465 P1110 - P1114: Testing and Inspection P1114 For diagnosis of code P1114 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1110 - P1114, ( P1111 P1112 P1113 1110 1111 1112 1113 1114 ) > System Information > System Diagnosis > P1112 > Page 466 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119, ( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115 P1115 - P1119: Testing and Inspection P1115 For diagnosis of code P1115 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119, ( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115 > Page 471 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119, ( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115 > Page 472 P1115 - P1119: Testing and Inspection P1116 For diagnosis of code P1116 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119, ( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115 > Page 473 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119, ( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115 > Page 474 P1115 - P1119: Testing and Inspection P1117 For diagnosis of code P1117 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119, ( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115 > Page 475 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 P1120 - P1124: Testing and Inspection P1120 For diagnosis of code P1120 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 480 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 481 P1120 - P1124: Testing and Inspection P1121 For diagnosis of code P1121 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 482 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 483 P1120 - P1124: Testing and Inspection P1124 For diagnosis of code P1124 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 484 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 P1125 - P1129: Testing and Inspection P1125 For diagnosis of code P1125 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 489 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 490 P1125 - P1129: Testing and Inspection P1127 For diagnosis of code P1127 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 491 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 492 P1125 - P1129: Testing and Inspection P1128 For diagnosis of code P1128 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 493 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 494 P1125 - P1129: Testing and Inspection P1129 For diagnosis of code P1129 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 495 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134, ( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 P1130 - P1134: Testing and Inspection P1130 For diagnosis of code P1130 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134, ( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 500 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134, ( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 501 P1130 - P1134: Testing and Inspection P1131 For diagnosis of code P1131 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134, ( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 502 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134, ( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 503 P1130 - P1134: Testing and Inspection P1132 For diagnosis of code P1132 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134, ( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 504 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1135 - P1139, ( P1136 P1137 P1138 1135 1136 1137 1138 1139 ) > System Information > System Diagnosis > P1137 P1135 - P1139: Testing and Inspection P1137 For diagnosis of code P1137 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1135 - P1139, ( P1136 P1137 P1138 1135 1136 1137 1138 1139 ) > System Information > System Diagnosis > P1137 > Page 509 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1135 - P1139, ( P1136 P1137 P1138 1135 1136 1137 1138 1139 ) > System Information > System Diagnosis > P1137 > Page 510 P1135 - P1139: Testing and Inspection P1138 For diagnosis of code P1138 refer to chart P072x - P1138 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1135 - P1139, ( P1136 P1137 P1138 1135 1136 1137 1138 1139 ) > System Information > System Diagnosis > P1137 > Page 511 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154, ( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 P1150 - P1154: Testing and Inspection P1150 For diagnosis of code P1150 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154, ( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 516 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154, ( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 517 P1150 - P1154: Testing and Inspection P1151 For diagnosis of code P1151 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154, ( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 518 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154, ( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 519 P1150 - P1154: Testing and Inspection P1152 For diagnosis of code P1152 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154, ( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 520 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1155 - P1159, ( P1156 P1157 P1158 1155 1156 1157 1158 1159 ) > System Information > System Diagnosis > P1157 P1155 - P1159: Testing and Inspection P1157 For diagnosis of code P1157 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1155 - P1159, ( P1156 P1157 P1158 1155 1156 1157 1158 1159 ) > System Information > System Diagnosis > P1157 > Page 525 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1155 - P1159, ( P1156 P1157 P1158 1155 1156 1157 1158 1159 ) > System Information > System Diagnosis > P1157 > Page 526 P1155 - P1159: Testing and Inspection P1158 For diagnosis of code P1158 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1155 - P1159, ( P1156 P1157 P1158 1155 1156 1157 1158 1159 ) > System Information > System Diagnosis > P1157 > Page 527 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1165 - P1169, ( P1166 P1167 P1168 1165 1166 1167 1168 1169 ) > System Information > System Diagnosis > P1168 P1165 - P1169: Testing and Inspection P1168 For diagnosis of code P1168 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1165 - P1169, ( P1166 P1167 P1168 1165 1166 1167 1168 1169 ) > System Information > System Diagnosis > P1168 > Page 532 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1165 - P1169, ( P1166 P1167 P1168 1165 1166 1167 1168 1169 ) > System Information > System Diagnosis > P1168 > Page 533 P1165 - P1169: Testing and Inspection P1169 For diagnosis of code P1169 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1165 - P1169, ( P1166 P1167 P1168 1165 1166 1167 1168 1169 ) > System Information > System Diagnosis > P1168 > Page 534 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184, ( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 P1180 - P1184: Testing and Inspection P1180 For diagnosis of code P1180 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184, ( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 539 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184, ( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 540 P1180 - P1184: Testing and Inspection P1181 For diagnosis of code P1181 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184, ( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 541 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184, ( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 542 P1180 - P1184: Testing and Inspection P1183 For diagnosis of code P1183 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184, ( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 543 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184, ( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 544 P1180 - P1184: Testing and Inspection P1184 For diagnosis of code P1184 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184, ( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 545 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1225 - P1229, ( P1226 P1227 P1228 1225 1226 1227 1228 1229 ) > System Information > System Diagnosis P1225 - P1229: Testing and Inspection For diagnosis of code P1229 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1225 - P1229, ( P1226 P1227 P1228 1225 1226 1227 1228 1229 ) > System Information > System Diagnosis > Page 550 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 P1230 - P1234: Testing and Inspection P1232 For diagnosis of code P1232 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 555 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 556 P1230 - P1234: Testing and Inspection P1233 For diagnosis of code P1233 refer to chart P1150 - P1401 NOTE 10: Perform Rear Electronics Module (REM) self-test/diagnostics. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 557 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 558 P1230 - P1234: Testing and Inspection P1234 For diagnosis of code P1234 refer to chart P1150 - P1401 NOTE 10: Perform Rear Electronics Module (REM) self-test/diagnostics. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 559 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 P1235 - P1239: Testing and Inspection P1235 For diagnosis of code P1235 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 564 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 565 P1235 - P1239: Testing and Inspection P1236 For diagnosis of code P1236 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 566 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 567 P1235 - P1239: Testing and Inspection P1237 For diagnosis of code P1237 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 568 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 569 P1235 - P1239: Testing and Inspection P1238 For diagnosis of code P1238 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 570 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1240 - P1244, ( P1241 P1242 P1243 1240 1241 1242 1243 1244 ) > System Information > System Diagnosis P1240 - P1244: Testing and Inspection For diagnosis of code P1244 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1240 - P1244, ( P1241 P1242 P1243 1240 1241 1242 1243 1244 ) > System Information > System Diagnosis > Page 574 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1245 - P1249, ( P1246 P1247 P1248 1245 1246 1247 1248 1249 ) > System Information > System Diagnosis > P1245 P1245 - P1249: Testing and Inspection P1245 For diagnosis of code P1245 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1245 - P1249, ( P1246 P1247 P1248 1245 1246 1247 1248 1249 ) > System Information > System Diagnosis > P1245 > Page 579 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1245 - P1249, ( P1246 P1247 P1248 1245 1246 1247 1248 1249 ) > System Information > System Diagnosis > P1245 > Page 580 P1245 - P1249: Testing and Inspection P1246 For diagnosis of code P1246 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1245 - P1249, ( P1246 P1247 P1248 1245 1246 1247 1248 1249 ) > System Information > System Diagnosis > P1245 > Page 581 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1260 - P1264, ( P1261 P1262 P1263 1260 1261 1262 1263 1264 ) > System Information > System Diagnosis P1260 - P1264: Testing and Inspection For diagnosis of code P1260 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1260 - P1264, ( P1261 P1262 P1263 1260 1261 1262 1263 1264 ) > System Information > System Diagnosis > Page 585 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1270 - P1274, ( P1271 P1272 P1273 1270 1271 1272 1273 1274 ) > System Information > System Diagnosis P1270 - P1274: Testing and Inspection For diagnosis of code P1270 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1270 - P1274, ( P1271 P1272 P1273 1270 1271 1272 1273 1274 ) > System Information > System Diagnosis > Page 589 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 P1285 - P1289: Testing and Inspection P1285 For diagnosis of code P1285 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 594 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 595 P1285 - P1289: Testing and Inspection P1288 For diagnosis of code P1288 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 596 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 597 P1285 - P1289: Testing and Inspection P1289 For diagnosis of code P1289 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 598 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1290 - P1294, ( P1291 P1292 P1293 1290 1291 1292 1293 1294 ) > System Information > System Diagnosis P1290 - P1294: Testing and Inspection For diagnosis of code P1290 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1290 - P1294, ( P1291 P1292 P1293 1290 1291 1292 1293 1294 ) > System Information > System Diagnosis > Page 602 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1295 - P1299, ( P1296 P1297 P1298 1295 1296 1297 1298 1299 ) > System Information > System Diagnosis P1295 - P1299: Testing and Inspection For diagnosis of code P1299 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1295 - P1299, ( P1296 P1297 P1298 1295 1296 1297 1298 1299 ) > System Information > System Diagnosis > Page 606 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1305 - P1309, ( P1306 P1307 P1308 1305 1306 1307 1308 1309 ) > System Information > System Diagnosis P1305 - P1309: Testing and Inspection For diagnosis of code P1309 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1305 - P1309, ( P1306 P1307 P1308 1305 1306 1307 1308 1309 ) > System Information > System Diagnosis > Page 611 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384, ( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 P1380 - P1384: Testing and Inspection P1380 For diagnosis of code P1380 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384, ( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 616 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384, ( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 617 P1380 - P1384: Testing and Inspection P1381 For diagnosis of code P1381 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384, ( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 618 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384, ( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 619 P1380 - P1384: Testing and Inspection P1383 For diagnosis of code P1383 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384, ( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 620 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1400 - P1404, ( P1401 P1402 P1403 1400 1401 1402 1403 1404 ) > System Information > System Diagnosis > P1400 P1400 - P1404: Testing and Inspection P1400 For diagnosis of code P1400 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1400 - P1404, ( P1401 P1402 P1403 1400 1401 1402 1403 1404 ) > System Information > System Diagnosis > P1400 > Page 626 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1400 - P1404, ( P1401 P1402 P1403 1400 1401 1402 1403 1404 ) > System Information > System Diagnosis > P1400 > Page 627 P1400 - P1404: Testing and Inspection P1401 For diagnosis of code P1401 refer to chart P1150 - P1401 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1400 - P1404, ( P1401 P1402 P1403 1400 1401 1402 1403 1404 ) > System Information > System Diagnosis > P1400 > Page 628 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 P1405 - P1409: Testing and Inspection P1405 For diagnosis of code P1405 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 633 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 634 P1405 - P1409: Testing and Inspection P1406 For diagnosis of code P1406 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 635 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 636 P1405 - P1409: Testing and Inspection P1408 For diagnosis of code P1408 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 637 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 638 P1405 - P1409: Testing and Inspection P1409 For diagnosis of code P1409 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 639 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1410 - P1414, ( P1411 P1412 P1413 1410 1411 1412 1413 1414 ) > System Information > System Diagnosis > P1413 P1410 - P1414: Testing and Inspection P1413 For diagnosis of code P1413 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1410 - P1414, ( P1411 P1412 P1413 1410 1411 1412 1413 1414 ) > System Information > System Diagnosis > P1413 > Page 644 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1410 - P1414, ( P1411 P1412 P1413 1410 1411 1412 1413 1414 ) > System Information > System Diagnosis > P1413 > Page 645 P1410 - P1414: Testing and Inspection P1414 For diagnosis of code P1414 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1410 - P1414, ( P1411 P1412 P1413 1410 1411 1412 1413 1414 ) > System Information > System Diagnosis > P1413 > Page 646 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1430 - P1434, ( P1431 P1432 P1433 1430 1431 1432 1433 1434 ) > System Information > System Diagnosis P1430 - P1434: Testing and Inspection For diagnosis of code P1432 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1430 - P1434, ( P1431 P1432 P1433 1430 1431 1432 1433 1434 ) > System Information > System Diagnosis > Page 650 For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1440 - P1444, ( P1441 P1442 P1443 1440 1441 1442 1443 1444 ) > System Information > System Diagnosis P1440 - P1444: Testing and Inspection For diagnosis of code P1443 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information , See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1450 - P1454, ( P1451 P1452 P1453 1450 1451 1452 1453 1454 ) > System Information > System Diagnosis > P1450 P1450 - P1454: Testing and Inspection P1450 For diagnosis of code P1450 refer to the system experiencing the problem. Computers and Control Systems P1405 - P1517 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1450 - P1454, ( P1451 P1452 P1453 1450 1451 1452 1453 1454 ) > System Information > System Diagnosis > P1450 > Page 658 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Evaporative Emissions System If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information, See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1450 - P1454, ( P1451 P1452 P1453 1450 1451 1452 1453 1454 ) > System Information > System Diagnosis > P1450 > Page 659 P1450 - P1454: Testing and Inspection P1451 For diagnosis of code P1451 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1450 - P1454, ( P1451 P1452 P1453 1450 1451 1452 1453 1454 ) > System Information > System Diagnosis > P1450 > Page 660 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 P1460 - P1464: Testing and Inspection P1460 For diagnosis of code P1460 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 665 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 666 P1460 - P1464: Testing and Inspection P1461 For diagnosis of code P1461 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 667 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 668 P1460 - P1464: Testing and Inspection P1462 For diagnosis of code P1462 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 669 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 670 P1460 - P1464: Testing and Inspection P1463 For diagnosis of code P1463 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 671 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 672 P1460 - P1464: Testing and Inspection P1464 For diagnosis of P1464 refer to the system experiencing the problem. Computers and Control Systems P1405 - P1517 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 673 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Heating and Air Conditioning If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Heating and Air Conditioning system diagnostic information, See: Heating and Air Conditioning/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1465 - P1469, ( P1466 P1467 P1468 1465 1466 1467 1468 1469 ) > System Information > System Diagnosis P1465 - P1469: Testing and Inspection For diagnosis of code P1469 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1465 - P1469, ( P1466 P1467 P1468 1465 1466 1467 1468 1469 ) > System Information > System Diagnosis > Page 677 For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1470 - P1474, ( P1471 P1472 P1473 1470 1471 1472 1473 1474 ) > System Information > System Diagnosis P1470 - P1474: Testing and Inspection For diagnosis of code P1474 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1470 - P1474, ( P1471 P1472 P1473 1470 1471 1472 1473 1474 ) > System Information > System Diagnosis > Page 681 For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1475 - P1479, ( P1476 P1477 P1478 1475 1476 1477 1478 1479 ) > System Information > System Diagnosis > P1477 P1475 - P1479: Testing and Inspection P1477 For diagnosis of code P1477 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1475 - P1479, ( P1476 P1477 P1478 1475 1476 1477 1478 1479 ) > System Information > System Diagnosis > P1477 > Page 686 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1475 - P1479, ( P1476 P1477 P1478 1475 1476 1477 1478 1479 ) > System Information > System Diagnosis > P1477 > Page 687 P1475 - P1479: Testing and Inspection P1479 For diagnosis of code P1479 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1475 - P1479, ( P1476 P1477 P1478 1475 1476 1477 1478 1479 ) > System Information > System Diagnosis > P1477 > Page 688 - Or information published by the manufacturer for this vehicle did not include this code For complete Engine Control diagnostic information , See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 P1500 - P1504: Testing and Inspection P1500 For diagnosis of code P1500 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 694 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 695 P1500 - P1504: Testing and Inspection P1501 For diagnosis of code P1501 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 696 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 697 P1500 - P1504: Testing and Inspection P1502 For diagnosis of code P1502 refer to chart P1405 - P1517 NOTE 12: Vehicle Speed information is provided by the Antilock Brake System (ABS). Perform complete diagnosis, See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 698 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 699 P1500 - P1504: Testing and Inspection P1504 For diagnosis of code P1504 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 700 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1505 - P1509, ( P1506 P1507 P1508 1505 1506 1507 1508 1509 ) > System Information > System Diagnosis > P1506 P1505 - P1509: Testing and Inspection P1506 For diagnosis of code P1506 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1505 - P1509, ( P1506 P1507 P1508 1505 1506 1507 1508 1509 ) > System Information > System Diagnosis > P1506 > Page 705 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1505 - P1509, ( P1506 P1507 P1508 1505 1506 1507 1508 1509 ) > System Information > System Diagnosis > P1506 > Page 706 P1505 - P1509: Testing and Inspection P1507 For diagnosis of code P1507 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1505 - P1509, ( P1506 P1507 P1508 1505 1506 1507 1508 1509 ) > System Information > System Diagnosis > P1506 > Page 707 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 P1515 - P1519: Testing and Inspection P1516 For diagnosis of code P1516 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 712 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 713 P1515 - P1519: Testing and Inspection P1517 For diagnosis of code P1517 refer to chart P1405 - P1517 If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 714 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 715 P1515 - P1519: Testing and Inspection P1518 For diagnosis of code P1518 refer to chart P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 716 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 717 P1515 - P1519: Testing and Inspection P1519 For diagnosis of code P1519 refer to chart P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 718 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1520 - P1524, ( P1521 P1522 P1523 1520 1521 1522 1523 1524 ) > System Information > System Diagnosis P1520 - P1524: Testing and Inspection For diagnosis of code P1520 refer to chart P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1520 - P1524, ( P1521 P1522 P1523 1520 1521 1522 1523 1524 ) > System Information > System Diagnosis > Page 722 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1545 - P1549, ( P1546 P1547 P1548 1545 1546 1547 1548 1549 ) > System Information > System Diagnosis P1545 - P1549: Testing and Inspection For diagnosis of code P1549 refer to chart P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1545 - P1549, ( P1546 P1547 P1548 1545 1546 1547 1548 1549 ) > System Information > System Diagnosis > Page 726 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1550 - P1554, ( P1551 P1552 P1553 1550 1551 1552 1553 1554 ) > System Information > System Diagnosis P1550 - P1554: Testing and Inspection For diagnosis of code P1550 refer to chart P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1550 - P1554, ( P1551 P1552 P1553 1550 1551 1552 1553 1554 ) > System Information > System Diagnosis > Page 730 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1570 - P1574, ( P1571 P1572 P1573 1570 1571 1572 1573 1574 ) > System Information > System Diagnosis P1570 - P1574: Testing and Inspection For diagnosis of code P1572 refer to chart P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1570 - P1574, ( P1571 P1572 P1573 1570 1571 1572 1573 1574 ) > System Information > System Diagnosis > Page 734 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1605 - P1609, ( P1606 P1607 P1608 1605 1606 1607 1608 1609 ) > System Information > System Diagnosis P1605 - P1609: Testing and Inspection For diagnosis of code P1605 refer to chart P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1605 - P1609, ( P1606 P1607 P1608 1605 1606 1607 1608 1609 ) > System Information > System Diagnosis > Page 739 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1630 - P1634, ( P1631 P1632 P1633 1630 1631 1632 1633 1634 ) > System Information > System Diagnosis P1630 - P1634: Testing and Inspection For diagnosis of code P1633 refer to chart P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1630 - P1634, ( P1631 P1632 P1633 1630 1631 1632 1633 1634 ) > System Information > System Diagnosis > Page 743 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 P1635 - P1639: Testing and Inspection P1635 For diagnosis of code P1635 refer to chart P1518 - P1781 NOTE 11: The vehicle ID block (VID) needs to be reprogrammed. Refer to Flash VID Block procedure, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 748 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 749 P1635 - P1639: Testing and Inspection P1636 For diagnosis of code P1636 refer to chart P1518 - P1781 NOTE 18: DTC P1636 indicates the PCM has lost communication with the Inductive Signature Chip. Replace PCM. If replacement is necessary refer to Flash Electically Erasable Programmable Read Only Memory (EEPROM), See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 750 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 751 P1635 - P1639: Testing and Inspection P1639 For diagnosis of code P1639 refer to chart P1518 - P1781 NOTE 11: The vehicle ID block (VID) needs to be reprogrammed. Refer to Flash VID Block procedure, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 752 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1640 - P1644, ( P1641 P1642 P1643 1640 1641 1642 1643 1644 ) > System Information > System Diagnosis P1640 - P1644: Testing and Inspection For diagnosis of code P1641 refer to chart P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1640 - P1644, ( P1641 P1642 P1643 1640 1641 1642 1643 1644 ) > System Information > System Diagnosis > Page 756 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1650 - P1654, ( P1651 P1652 P1653 1650 1651 1652 1653 1654 ) > System Information > System Diagnosis > P1650 P1650 - P1654: Testing and Inspection P1650 For diagnosis of code P1650 refer to chart P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1650 - P1654, ( P1651 P1652 P1653 1650 1651 1652 1653 1654 ) > System Information > System Diagnosis > P1650 > Page 761 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1650 - P1654, ( P1651 P1652 P1653 1650 1651 1652 1653 1654 ) > System Information > System Diagnosis > P1650 > Page 762 P1650 - P1654: Testing and Inspection P1651 For diagnosis of code P1651 refer to chart P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1650 - P1654, ( P1651 P1652 P1653 1650 1651 1652 1653 1654 ) > System Information > System Diagnosis > P1650 > Page 763 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1701 P1700 - P1704: Testing and Inspection P1701 For diagnosis of code P1701 refer to chart P0705-P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1701 > Page 769 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1701 > Page 770 P1700 - P1704: Testing and Inspection P1702 For diagnosis of code P1702 refer to chart P1702-P1900 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1701 > Page 771 P1700 - P1704: Testing and Inspection P1703 For diagnosis of code P1703 refer to charts P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1701 > Page 772 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1701 > Page 773 P1700 - P1704: Testing and Inspection P1704 For diagnosis of code P1704 refer to chart P0102-P1705 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1701 > Page 774 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 P1705 - P1709: Testing and Inspection P1705 Manual Transmission For diagnosis of code P1705 refer to chart P1518 - P1781 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 > Page 779 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Automatic Transmission For diagnosis of code P1705 refer to chart P0102-P1705 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 > Page 780 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 > Page 781 P1705 - P1709: Testing and Inspection P1709 For diagnosis of code P1709 refer to chart P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 > Page 782 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1713 P1710 - P1714: Testing and Inspection P1713 For diagnosis of code P1713 refer to chart P1702-P1900 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1713 > Page 787 P1710 - P1714: Testing and Inspection P1714 For diagnosis of code P1714 refer to chart P0705-P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1713 > Page 788 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 P1715 - P1719: Testing and Inspection P1715 For diagnosis of code P1715 refer to chart P0720-P1740 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 793 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 794 P1715 - P1719: Testing and Inspection P1716 For diagnosis of code P1716 refer to chart P0720-P1740 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 795 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 796 P1715 - P1719: Testing and Inspection P1717 For diagnosis of code P1717 refer to chart P0720-P1740 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 797 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 798 P1715 - P1719: Testing and Inspection P1718 For diagnosis of code P1718 refer to chart P1702-P1900 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1725 - P1729, ( P1726 P1727 P1728 1725 1726 1727 1728 1729 ) > System Information > System Diagnosis P1725 - P1729: Testing and Inspection For diagnosis of code P1729 refer to chart P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1725 - P1729, ( P1726 P1727 P1728 1725 1726 1727 1728 1729 ) > System Information > System Diagnosis > Page 802 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis P1740 - P1744: Testing and Inspection For diagnosis of code P1740 refer to chart P0720-P1740 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > Page 806 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749, ( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 P1745 - P1749: Testing and Inspection P1746 For diagnosis of code P1746 refer to chart P0705-P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749, ( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 > Page 811 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749, ( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 > Page 812 P1745 - P1749: Testing and Inspection P1747 For diagnosis of code P1747 refer to chart P0712-P1780 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749, ( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 > Page 813 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1760 - P1764, ( P1761 P1762 P1763 1760 1761 1762 1763 1764 ) > System Information > System Diagnosis > P1763 P1760 - P1764: Testing and Inspection P1763 For diagnosis of code P1763 refer to chart Part 4 Of 5 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1760 - P1764, ( P1761 P1762 P1763 1760 1761 1762 1763 1764 ) > System Information > System Diagnosis > P1763 > Page 818 For complete Instrument Panel diagnostic information, See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1760 - P1764, ( P1761 P1762 P1763 1760 1761 1762 1763 1764 ) > System Information > System Diagnosis > P1763 > Page 819 P1760 - P1764: Testing and Inspection P1764 For diagnosis of code P1764 refer to chart Part 4 Of 5 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1760 - P1764, ( P1761 P1762 P1763 1760 1761 1762 1763 1764 ) > System Information > System Diagnosis > P1763 > Page 820 For complete Instrument Panel diagnostic information, See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 P1780 - P1784: Testing and Inspection P1780 For diagnosis of code P1780 refer to chart P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 825 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 826 P1780 - P1784: Testing and Inspection P1781 For diagnosis of code P1781 refer to chart P1518 - P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 827 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 828 P1780 - P1784: Testing and Inspection P1783 For diagnosis of code P1783 refer to chart P0712-P1780 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 829 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1900-P19ZZ > P1900 - P1904, ( P1901 P1902 P1903 1900 1901 1902 1903 1904 ) > System Information > System Diagnosis > Manual Transmission P1900 - P1904: Testing and Inspection Manual Transmission For diagnosis of code P1900 refer to charts P1783 - P1900 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1900-P19ZZ > P1900 - P1904, ( P1901 P1902 P1903 1900 1901 1902 1903 1904 ) > System Information > System Diagnosis > Manual Transmission > Page 835 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1900-P19ZZ > P1900 - P1904, ( P1901 P1902 P1903 1900 1901 1902 1903 1904 ) > System Information > System Diagnosis > Manual Transmission > Page 836 P1900 - P1904: Testing and Inspection Automatic Transmission For diagnosis of code P1900 refer to chart P1702-P1900 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Accessory Delay Relay: Locations The Generic Electronic Module (GEM) / Central Timer Module (CTM) Controls the Accessory Delay Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 843 Accessory Delay Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Alarm Module: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 847 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 848 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 851 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 852 Alarm Module: Diagrams Remote Anti-Theft Personality Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 853 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 854 Alarm Module: Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 855 Alarm Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 856 Alarm Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Locations > Page 860 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Specifications Multifunction Electronic Control Modules: Specifications Remote Anti-Theft Personality Module 2.3-3.3 Nm Battery Ground Cable Screws 7-10 Nm GEM/CTM Screw 1.6-2.0 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Specifications > Page 864 Multifunction Electronic Control Modules: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Specifications > Page 865 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions Multifunction Electronic Control Modules: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 868 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 869 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 870 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 871 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 872 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 873 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 874 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 875 Multifunction Electronic Control Modules: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 876 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 877 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 878 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 879 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 880 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 881 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 882 Multifunction Electronic Control Modules: Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 883 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 884 Multifunction Electronic Control Modules: Electrical Diagrams Diagram 59-1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 885 Diagram 59-2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 886 Diagram 59-3 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 887 Diagram 59-4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 888 Diagram 59-5 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 889 Diagram 59-6 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 890 Multifunction Electronic Control Modules: Description and Operation The multifunction modules consist of the following: ^ generic electronic module (GEM)/central timer module (CTM) ^ remote anti-theft personality (RAP) module The remote anti-theft personality (RAP) module controls the keyless entry, and computer operated locks systems. The GEM/CTM controls the following features: ^ wiper/washer (front/rear) ^ warning chime ^ battery saver ^ illuminated entry and courtesy lamps ^ driver one touch down power window (GEM only) ^ accessory delay ^ 4 wheel drive (GEM only) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 891 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Module Generic Electronic (GEM)/Central Timer (CTM) Multifunction Electronic Control Modules: Service and Repair Module - Generic Electronic (GEM)/Central Timer (CTM) REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 2. Remove the radio chassis; refer to Radio, Stereo, and Compact Disc. 3. Remove the center instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 4. Remove the GEM/CTM. 1 Remove the screw. 2 Disconnect the four connectors from the GEM/CTM. 3 Remove the GEM/CTM. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Module Generic Electronic (GEM)/Central Timer (CTM) > Page 894 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Module Generic Electronic (GEM)/Central Timer (CTM) > Page 895 Multifunction Electronic Control Modules: Service and Repair Module - Remote Anti-Theft Personality (RAP) REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these static charges, damage may result. 2. Remove the LH rear quarter trim panel. 3. Disconnect the two remote anti-theft personality (RAP) module electrical connectors. 4. Remove the two RAP module fasteners. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Module Generic Electronic (GEM)/Central Timer (CTM) > Page 896 5. Remove the RAP module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions Keyless Entry Module: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 902 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 903 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 904 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 905 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 906 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 907 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 908 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 909 Keyless Entry Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 910 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 911 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 912 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 913 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 914 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 915 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Page 916 Keyless Entry Module: Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Page 917 Keyless Entry Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Page 918 Keyless Entry Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations Parking Assist Control Module: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 925 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 926 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 927 Parking Assist Control Module: Service and Repair REMOVAL 1. Remove the jack storage panel. 2. Remove the parking aid module. 1 Disconnect the electrical connector. 2 Remove the screws. 3 Remove the parking aid module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions Keyless Entry Module: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 934 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 935 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 936 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 937 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 938 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 939 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 940 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 941 Keyless Entry Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 942 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 943 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 944 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 945 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 946 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 947 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Page 948 Keyless Entry Module: Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Page 949 Keyless Entry Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Page 950 Keyless Entry Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Locations > Page 954 Power Door Lock Control Module: Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Locations > Page 955 Power Door Lock Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Locations > Page 956 Power Door Lock Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations Power Door Lock Relay: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 960 4 Door W/Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 961 2 Door W/Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Testing and Inspection > Two Door Models Power Door Lock Relay: Testing and Inspection Two Door Models Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Testing and Inspection > Two Door Models > Page 964 Power Door Lock Relay: Testing and Inspection Four Door Models Driver Door Unlock Relay Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Testing and Inspection > Two Door Models > Page 965 Door Lock/Unlock Relays Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams Power Seat Control Module: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Page 969 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Service Precautions > Technician Safety Information Power Seat Control Module: Technician Safety Information WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Service Precautions > Technician Safety Information > Page 972 Power Seat Control Module: Vehicle Damage Warnings CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Service Precautions > Page 973 Power Seat Control Module: Service and Repair REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the seat track assembly. For additional information, refer to Seat-Track, Limited and 6-Way Power. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way Power, Removal and Installation. 3. Remove the Driver Seat Module (DSM). 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the DSM. INSTALLATION CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Service Precautions > Page 974 1. Install the DSM. 1 Connect the electrical connectors. 2 Position the DSM. 3 Install the screws. 2. Install the seat track. For additional information, refer to Seat-Track, Limited and 6-Way Power. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way Power, Removal and Installation. 3. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. Prove out the air bag system. For additional information, refer to Air Bag Systems. 5. Check the restraint system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Left Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Left > Page 979 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 980 Seat Heater Control Module: Service and Repair REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the power front seat track. For additional information refer to Seat-Track, Limited and 6-Way Power. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way Power, Removal and Installation. 3. Disconnect the heated seat module electrical connector. 4. Remove the heated seat module. 1 Release the clip. 2 Remove the heated seat module. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 981 CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 1. Install the heated seat module. 2. Connect the heated seat module electrical connector. 3. Install the power front seat track. For additional information, refer to Seat-Track, Limited and 6-Way Power. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way Power, Removal and Installation. 4. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Prove out the air bag system. For additional information, refer to Air Bag Systems. 6. Check the restraint system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications Anti-lock brake control module bolts 1.8 - 1.9 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 986 Electronic Brake Control Module: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 987 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 988 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 989 Electronic Brake Control Module: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is part of, please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 990 Electronic Brake Control Module: Service and Repair Removal 1. CAUTION: Prior to removal of the module, it is necessary to upload module configuration information to the scan tool. This information needs to be downloaded into the new module once installed. Disconnect the battery ground cable. 2. Remove the hydraulic control unit bolts. 3. Disconnect the anti-lock brake control module electrical connectors. 4. Remove the anti-lock brake control module. 1 Remove the bolts. 2 Remove the control module. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 991 1. CAUTION: Once the new module is installed, it is necessary to download the module configuration information from the scan tool into the module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 997 Electronic Automatic Temperature Control Electrical Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 998 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 1000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 1001 Blower Motor Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Compressor Clutch Relay Compressor Clutch Relay: Locations Compressor Clutch Relay Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Compressor Clutch Relay > Page 1006 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Compressor Clutch Relay > Page 1007 Compressor Clutch Relay: Locations Compressor Cut-Off Relay Manual A/C Electrical Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Compressor Clutch Relay > Page 1008 Electronic Automatic Temperature Control Electrical Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 1009 Compressor Clutch Relay: Description and Operation WIDE OPEN THROTTLE A/C CUT-OFF The Wide Open Throttle A/C Cut-Off Relay (may be referred to as the A/C clutch relay) is normally open. There is no direct electrical connection between the A/C switch or EATC Module and the A/C clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACP (SW), A/C Cycling Switch (ACCS)). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine rpm, throttle position), the PCM will ground the Wide Open Throttle A/C (WAC) output, closing the relay contacts and sending voltage to the A/C clutch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 1010 Compressor Clutch Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From Floor Ducts Control Module HVAC: Customer Interest A/C - Cold Air Blows From Floor Ducts Article No. 02-8-5 04/29/02 CLIMATE CONTROL - ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC) BLOWS COLD AIR FROM FLOOR DUCTS - VEHICLES PRODUCED BEFORE 9/30/2000 ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles produced before 9/30/2000 equipped with Electronic Automatic Temperature Control (EATC) may blow cold air from the floor ducts after the climate control system reaches a steady state in AUTO mode after switching from the FLOOR/DEFROST mode position to the FLOOR mode position, usually after driving for 15-30 minutes. This may be caused by the software version of the EATC Module. ACTION Update the software version or replace the EATC Module. Refer to the following Service Procedure for details. SERVICE PROCEDURE On vehicles equipped with the following EATC modules, F87H-18C612-BD, F87H-18C612-BE, XL2H-18C612-AA, or XL2H-18C612-AB, use NGS with Service Card Version 9.0 or later to update the EATC module software. On all other modules, replace the EATC module with service part YL2Z-19980-AA. Refer to section 412-04 of the appropriate model year Workshop Manual for removal and installation procedures. Use NGS with diagnostic card installed to verify the EATC module ID number (Engineering Part Number). NGS Procedure for Identifying EATC Module ID Number 1. Select "Diagnostics". 2. Select "EATC". 3. Select "Module I.D". NGS will display the EATC module I.D. number (Engineering Part Number). Vehicles that have been previously updated with this software will display "GO7H-BA". NGS Procedure for Updating Software 1. Select "Service Bay Functions". 2. Select "EATC" from module list. 3. Select "Module Configuration". 4. Select "99-01 Explorer" or "99-01 Mountaineer". Upon completion of the software upgrade, NGS will change the EATC module I.D to G07H-BA and display "Module Data Download Successfull". If the EATC module has been updated previously, or the module is not one of the modules listed as being capable of being updated, NGS will display "Can not update with the NGS". If the module is not capable of being updated, replace the module with part number YL2Z-19980-AA as listed above. Parts Block Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From Floor Ducts > Page 1019 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208300, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From Floor Ducts Control Module HVAC: All Technical Service Bulletins A/C - Cold Air Blows From Floor Ducts Article No. 02-8-5 04/29/02 CLIMATE CONTROL - ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC) BLOWS COLD AIR FROM FLOOR DUCTS - VEHICLES PRODUCED BEFORE 9/30/2000 ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles produced before 9/30/2000 equipped with Electronic Automatic Temperature Control (EATC) may blow cold air from the floor ducts after the climate control system reaches a steady state in AUTO mode after switching from the FLOOR/DEFROST mode position to the FLOOR mode position, usually after driving for 15-30 minutes. This may be caused by the software version of the EATC Module. ACTION Update the software version or replace the EATC Module. Refer to the following Service Procedure for details. SERVICE PROCEDURE On vehicles equipped with the following EATC modules, F87H-18C612-BD, F87H-18C612-BE, XL2H-18C612-AA, or XL2H-18C612-AB, use NGS with Service Card Version 9.0 or later to update the EATC module software. On all other modules, replace the EATC module with service part YL2Z-19980-AA. Refer to section 412-04 of the appropriate model year Workshop Manual for removal and installation procedures. Use NGS with diagnostic card installed to verify the EATC module ID number (Engineering Part Number). NGS Procedure for Identifying EATC Module ID Number 1. Select "Diagnostics". 2. Select "EATC". 3. Select "Module I.D". NGS will display the EATC module I.D. number (Engineering Part Number). Vehicles that have been previously updated with this software will display "GO7H-BA". NGS Procedure for Updating Software 1. Select "Service Bay Functions". 2. Select "EATC" from module list. 3. Select "Module Configuration". 4. Select "99-01 Explorer" or "99-01 Mountaineer". Upon completion of the software upgrade, NGS will change the EATC module I.D to G07H-BA and display "Module Data Download Successfull". If the EATC module has been updated previously, or the module is not one of the modules listed as being capable of being updated, NGS will display "Can not update with the NGS". If the module is not capable of being updated, replace the module with part number YL2Z-19980-AA as listed above. Parts Block Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From Floor Ducts > Page 1025 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208300, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control - Blower Control Service Tips Control Module HVAC: All Technical Service Bulletins Climate Control - Blower Control Service Tips Article No. 00-21-3 10/16/00 CLIMATE CONTROL - EATC - BLOWER MOTOR CONTROL SERVICE TIPS FORD: 1990-1993 THUNDERBIRD 1990-2001 CROWN VICTORIA 1995-2001 EXPLORER LINCOLN: 1990-2001 TOWN CAR 2000-2001 LS MERCURY: 1990-1993 COUGAR 1990-2001 GRAND MARQUIS 1997-2001 MOUNTAINEER ISSUE The following service procedure has been developed to aid technicians in diagnosing EATC/DATC system blower motor control concerns. ACTION Refer to the following Service Procedure as an aid in helping diagnose blower motor control concerns. SERVICE PROCEDURE 1. Check blower motor operation in all speeds. ^ If the blower motor does not operate in any speed, refer to Step 2. ^ If the blower motor continuously operates in HIGH, refer to the appropriate pinpoint test in the Service/Workshop Manual. ^ If the blower motor does not operate in HIGH speed, refer to Step 3. ^ If the blower motor does not operate at speeds other than HIGH, refer to Step 4. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control - Blower Control Service Tips > Page 1030 NOTE: REFER TO FIGURE 1 FOR CONNECTOR VIEW. 2. Refer to the appropriate pinpoint test in the Service/Workshop Manual, except for checking the EATC/DATC module. When checking the EATC/DATC module, set the blower motor speed to HIGH blower and measure the voltage between the blower motor high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is 5 ohms or less, repair the circuit. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). Retest the system for normal operation. 3. Set the blower speed control to HIGH and measure the voltage between the blower motor control high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. 4. Set the blower speed control to any speed other than HIGH and measure the voltage between the blower motor control blower control circuit (Pin 2 at the controller) and ground at the EATC/DATC module. a. If the voltage is below 1 volt, measure the resistance between the blower motor speed controller connector Pin 1 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. b. If the voltage is between 1 and 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 2 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. c. If the voltage is greater than 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 1 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less; install a new blower motor speed controller (19E624). If. the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control - Blower Control Service Tips > Page 1031 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208300, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control - Blower Control Service Tips Control Module HVAC: All Technical Service Bulletins Climate Control - Blower Control Service Tips Article No. 00-21-3 10/16/00 CLIMATE CONTROL - EATC - BLOWER MOTOR CONTROL SERVICE TIPS FORD: 1990-1993 THUNDERBIRD 1990-2001 CROWN VICTORIA 1995-2001 EXPLORER LINCOLN: 1990-2001 TOWN CAR 2000-2001 LS MERCURY: 1990-1993 COUGAR 1990-2001 GRAND MARQUIS 1997-2001 MOUNTAINEER ISSUE The following service procedure has been developed to aid technicians in diagnosing EATC/DATC system blower motor control concerns. ACTION Refer to the following Service Procedure as an aid in helping diagnose blower motor control concerns. SERVICE PROCEDURE 1. Check blower motor operation in all speeds. ^ If the blower motor does not operate in any speed, refer to Step 2. ^ If the blower motor continuously operates in HIGH, refer to the appropriate pinpoint test in the Service/Workshop Manual. ^ If the blower motor does not operate in HIGH speed, refer to Step 3. ^ If the blower motor does not operate at speeds other than HIGH, refer to Step 4. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control - Blower Control Service Tips > Page 1037 NOTE: REFER TO FIGURE 1 FOR CONNECTOR VIEW. 2. Refer to the appropriate pinpoint test in the Service/Workshop Manual, except for checking the EATC/DATC module. When checking the EATC/DATC module, set the blower motor speed to HIGH blower and measure the voltage between the blower motor high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is 5 ohms or less, repair the circuit. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). Retest the system for normal operation. 3. Set the blower speed control to HIGH and measure the voltage between the blower motor control high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. 4. Set the blower speed control to any speed other than HIGH and measure the voltage between the blower motor control blower control circuit (Pin 2 at the controller) and ground at the EATC/DATC module. a. If the voltage is below 1 volt, measure the resistance between the blower motor speed controller connector Pin 1 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. b. If the voltage is between 1 and 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 2 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. c. If the voltage is greater than 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 1 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less; install a new blower motor speed controller (19E624). If. the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control - Blower Control Service Tips > Page 1038 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208300, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 1041 Control Module HVAC: Locations Blower Motor Speed Control Electronic Automatic Temperature Control Electrical Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 1042 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Electronic Climate Control Module Control Module HVAC: Diagrams Electronic Climate Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Electronic Climate Control Module > Page 1045 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Page 1046 Control Module HVAC: Description and Operation The blower speed control is located on the evaporator housing in the engine compartment. - The function of the blower motor speed control is to convert low power signals from the electronic automatic temperature control module to a high current, variable ground feed for the blower motor. - The blower motor speed is infinitely variable and is controlled by the electronic automatic temperature control module software. - A delay function provides a gradual increase or decrease in blower motor speed under all conditions. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device Control Module: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1053 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1054 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1055 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1056 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1057 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1058 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1059 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1060 Audible Warning Device Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1061 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1062 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1063 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1064 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1065 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1066 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 1067 Audible Warning Device Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 1068 Audible Warning Device Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 1069 Audible Warning Device Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Gauge Module > Component Information > Description and Operation Fuel Gauge Module: Description and Operation NOTE: - The fuel gauge and instrument cluster gauge amplifier must be replaced as a set. The fuel gauge and instrument cluster gauge amplifier are calibrated together. - If the ignition key is left in the ON position during fueling, a slow to respond fuel gauge indication may result. The ignition key must be placed in the OFF position during or after refueling for accurate fuel gauge indication. The instrument cluster gauge amplifier electrically averages the fuel sender readings so the gauge displays the actual fuel level and not the fluctuations due to fuel sloshing. The amplifier also supplies the signal to illuminate the CHECK GAGE indicator to indicate low fuel, high engine coolant temperature, or low engine oil pressure. The gauge amplifier is a small printed circuit board located in a pocket on the back of the instrument cluster. The electrical connections are made with a spring-type connector. There are no provisions for calibration or adjustment. The fuel gauge and the instrument cluster gauge amplifier must be replaced as a unit. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Gauge Module > Component Information > Description and Operation > Page 1073 Fuel Gauge Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Gauge Module > Component Information > Description and Operation > Page 1074 Fuel Gauge Module: Service and Repair Service and Repair The fuel gauge and instrument cluster gauge amplifier (Slosh Module) are calibrated together and must be replaced as a set. For further information regarding this component please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Locations > Page 1078 Instrument Panel Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Locations > Page 1079 Instrument Panel Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Locations > Page 1080 Instrument Panel Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations Panel Illumination Control Module: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations > Page 1084 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations > Page 1085 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations > Page 1086 Panel Illumination Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations > Page 1087 Panel Illumination Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations > Page 1088 Panel Illumination Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations Battery Discharge Protection Relay: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 1093 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 1094 Battery Discharge Protection Relay: Description and Operation The following components are under the control of the battery saver relay: ^ Delayed accessory relay. ^ Overhead interior lamp with map lamps. ^ Overhead interior lamp switch. ^ Interior lamp relay coil. The battery saver relay becomes active (relay coil is energized) when the GEM is in the awake mode, and is deactivated (relay coil is de-energized) when the GEM is in the sleep mode. The battery saver will remain active until the ignition state is not ACC or RUN and 45 minutes have passed since the last active input. At that time, the relay will be deactivated and power to the above circuits will terminate. Five minutes after the battery saver relay has become deactivated, the GEM will go into a lower power state known as sleep mode. In the sleep mode, the GEM will deactivate all outputs and will monitor only select inputs. Logical characteristics of the GEM battery saver mode are as follows: Feature Input: ^ Sleep/awake mode status. Feature Output: ^ Battery saver relay control (open circuit in sleep mode, grounded when awake). For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 1095 Battery Discharge Protection Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 1096 Battery Discharge Protection Relay: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications Daytime Running Lamp Control Unit: Specifications Daytime Running Lamps Control Module Bolts 3 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 1100 Daytime Running Lamp Control Unit: Locations Left front corner of engine. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 1101 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 1102 Daytime Running Lamp Control Unit: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the daytime running lamps (DRL) control module. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the DRL control module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Locations > Page 1106 Exterior Lighting Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Locations > Page 1107 Exterior Lighting Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Locations > Page 1108 Exterior Lighting Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 1112 Fog/Driving Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Dimmer Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Dimmer Relay > Component Information > Locations > Page 1116 Headlamp Dimmer Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 1120 Headlamp Relay: Testing and Inspection Testing an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper wires and 73 Digital Multimeter. Remove the relay to be tested from the power distribution box, fuse junction panel or individual connector. Terminals Component Testing Procedure Schematic Use 73 Digital Multimeter to check for continuity between terminal 2 and all other terminals. If resistance is 5 ohms or less between terminal 2 and any Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 1121 other terminal, replace the relay. If resistance is greater than 5 ohms, continue the test. Use two jumper wires to connect relay terminals 1 and 3 directly to the positive battery terminal. Set 73 Digital Multimeter in volts position and check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect the third jumper wire to terminal 2, and ground the jumper wire to chassis ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 1125 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 1126 Horn Relay: Testing and Inspection Terminals Component Testing Procedure Schematic Use 73 Digital Multimeter to check for continuity between terminal 2 and all other terminals. If resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue the test. Use two jumper wires to connect relay terminal 1 and terminal 3 directly to the positive battery terminal. Set 73 Digital Multimeter in the volts position and check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 2 and ground the jumper wire to a known good Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 1127 ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions Interior Lighting Module: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1133 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1134 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1135 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1136 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1137 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1138 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1139 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1140 Interior Lighting Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1141 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1142 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1143 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1144 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1145 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1146 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Page 1147 Interior Lighting Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Page 1148 Interior Lighting Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Page 1149 Interior Lighting Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 1153 Interior Lighting Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Relay Module Parking Lamp Relay is located in the relay module. Relay module is located behind center of I/P. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 1157 Parking Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Power Distribution Relay: Locations Trailer Tow Park Lamp Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 1171 4 Door W/Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 1172 2 Door W/Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 1173 Power Distribution Relay: Testing and Inspection Trailer Tow Park Lamp Relay Test Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1178 Fuse 1 - 18 Fuse 19 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1179 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1180 Fuse 1 - 10 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1181 Fuse 11 - 31 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1182 Fuse 32 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1183 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1184 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1185 Relays Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1186 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1187 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1188 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 1191 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 1192 Relay Box: Diagrams Auxiliary Relay Box #2 2 Door W/o Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 1193 4 Door W/Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 1194 2 Door W/Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1197 Fuse 1 - 18 Fuse 19 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1198 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1199 Fuse 1 - 10 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1200 Fuse 11 - 31 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1201 Fuse 32 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1202 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1203 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1204 Relays Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1205 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1206 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1207 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures Powertrain Control Module: Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 1214 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 1215 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Technical Service Bulletins > Page 1216 Powertrain Control Module: Specifications PCM Connector 5 - 7 Nm Powertrain Control Module Connector Bolt 7 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Technical Service Bulletins > Page 1217 Powertrain Control Module: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Technical Service Bulletins > Page 1218 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Technical Service Bulletins > Page 1219 Powertrain Control Module: Diagrams Part (1 Of 3) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Technical Service Bulletins > Page 1220 Part (2 Of 3) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Technical Service Bulletins > Page 1221 Part (3 Of 3) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Description and Operation > General Description and Operation Powertrain Control Module: Description and Operation General Description and Operation The PCM performs the following functions: ^ accepts input from various engine sensors to compute the required fuel flow rate necessary to maintain a prescribed air/fuel ratio throughout the entire engine operational range. ^ outputs a command to the fuel injectors to meter the appropriate quantity of fuel. ^ determines and compensates for the age of the vehicle and its uniqueness, also automatically senses and compensates for changes in altitude. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Description and Operation > General Description and Operation > Page 1224 Powertrain Control Module: Description and Operation Standard Models (Non BI-Fuel) POWERTRAIN CONTROL MODULE - VEHICLE SPEED OUTPUT (VSO) The PCM-VSO (Powertrain Control Module - Vehicle Speed Output) speed signal subsystem generates vehicle speed information for distribution to the vehicle's electrical/electronic modules and subsystems that require vehicle speed data. This subsystem senses the transmission output shaft speed with a sensor. The data is processed by the PCM, and distributed as a hard-wired signal or as a multiplexed data message. The key features of the PCM-VSO system are to: ^ Infer vehicle movement from the output shaft sensor signal ^ Convert transmission output shaft rotational information to vehicle speed information ^ Compensate for tire size and axle ratio with a programmed calibration variable ^ Utilize a transfer case sensor for four wheel drive applications ^ Distribute vehicle speed information as a multiplexed message and/or an analog signal The signal from a non-contact shaft sensor (Output Shaft Sensor--OSS or Transfer Case Shaft Sensor--TCSS) mounted on the transmission (automatics, manuals, or 4X4 transfer cases) is sensed directly by the PCM. The PCM converts the OSS or TCSS information to 8000 pulses per mile, based on a tire and axle ratio conversion factor. This conversion factor is programmed into the PCM at the time the vehicle is assembled and can be reprogrammed in the field for servicing changes in the tire size and axle ratio. The PCM transmits the computed vehicle speed and distance traveled information to all the vehicle speed signal users on the vehicle. VSO information can be transmitted by a hard-wired interface between the vehicle speed signal user and the PCM, or by Speed and Odometer SCP multiplexed data messages. The VSO hard-wired signal wave form is a DC square wave with a voltage level of 0 to VBAT. Typical output operating range is 2.22Hz per MPH (1.3808 Hz pr 1 Km/h). Multiplexed data for speed and distance data are transmitted as separate SCP messages over the SCP multiplex link. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Flash Electrically Eraseable Programmable Read Only Memory Powertrain Control Module: Service and Repair Flash Electrically Eraseable Programmable Read Only Memory Flash Electrically Eraseable Programmable Read Only Memory - Flash EEPROM Description Flash Electrically Eraseable Programmable Read Only Memory (EEPROM) is contained in an Integrated Circuit (IC) internal to the Powertrain Control Module (PCM). The EEPROM contains the vehicle strategy including calibration information specific to the vehicle and is capable of being reprogrammed or reflashed repeatedly. As part of the calibration there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM as under Programming the VID Block for a Replacement PCM. Failure to perform this procedure may generate fault code: P1639, VID Block not programmed or is corrupt. The VID block in an existing Powertrain Control Module (PCM). can also be tailored to accommodate various hardware changes made to the vehicle since production. Failure to perform this procedure properly may generate fault code: P1635, Tire/Axle Ratio out of Acceptable Range. This is described under Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the VIN number, octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control and four wheel drive electronic shift on the fly versus manual shift on the fly. Only items applicable to vehicle hardware and supported by the VID block will be displayed on the scan tool. When changing items in the VID block, the strategy will place range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool will display a message indicating the need to flash the PCM again to reset the VID block. Each of the procedures described below use the Worldwide Diagnostic System (WDS). Reprogramming can be performed by a local Ford dealer for any non Ford facility. There are other Enhanced Scan Tools that may have reprogramming capabilities available. Refer to the diagnostic tool manufacturers users manual for details. Programming the VID Block for a Replacement PCM A new PCM will contain the latest strategy and calibration level for a particular vehicle. However, the VID block will be blank and will need programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM and the second is manual data entry into the new PCM. Automatic data transfer will be performed if the old PCM is capable of communicating. This is done by the use of a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can now be downloaded to the new PCM after it has been replaced. Manual data entry must be performed if the old module is damaged and is incapable of communicating. Remove and replace the old PCM. You may be instructed to contact the "AS BUILT" data center for the information needed to manually update the VID block with the scan tool. Contact the center ONLY if the old PCM cannot be used or the data is corrupt. For Ford L-M technician's, contact your National Hotline for "AS Built" data. Non Ford technicians, use the Fed World website at "fedworld.gov". Select Auto Service Information and search for "Calibrations" or "Vehicle Calibrations" then specify vehicle manufacturer, model name and model year as required. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate vehicle hardware. Refer to PCM/Module Reprogramming on the Scan Tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM will need to be completely reprogrammed. This is due to changes made to the strategy or calibration after production or the need to reset the VID block because it has reached its limit. Refer to PCM/Module Reprogramming on the Scan Tool. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Flash Electrically Eraseable Programmable Read Only Memory > Page 1227 Powertrain Control Module: Service and Repair Removal and Installation REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Powertrain Control Module (PCM) electrical connector. 3. Remove the nuts and the PCM cover. 4. Remove the PCM. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1231 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1232 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Emission Control Systems > Air Injection Pump Relay > Component Information > Description and Operation Air Injection Pump Relay: Description and Operation SOLID STATE RELAY Solid State Relay The solid state relay (Figure 124) switches the high current required for operation of the electric AIR pump. Input control to the solid state relay comes from the Powertrain Control Module (PCM). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Page 1241 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Page 1242 Fuel Pump Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1246 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1247 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications Air Bag Control Module: Specifications Restraint Control Module Bracket 12 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 1252 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 1253 Air Bag Control Module: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 1254 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 1255 Air Bag Control Module: Description and Operation The Restraints Control Module (RCM) carries out the following functions: ^ signals the inflators to deploy the air bags in the event of a deployable crash. ^ monitors the air bag Supplemental Restraint System (SRS) for faults. ^ illuminates the air bag indicator if a fault is detected. ^ flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected. ^ communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble Codes (DTCs). ^ signals the Generic Electronic Module (GEM) to activate a chime if the air bag indicator is not available and another SRS fault exists. NOTE: The safety sensor is internal to the RCM and is not serviced separately. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the RCM will illuminate the air bag indicator located in the instrument cluster. When the ignition is cycled (turned off and then on), the air bag indicator will prove out by lighting for six seconds and then off for two seconds. After the prove out, the air bag indicator will then flash the two-digit LFC. If an SRS fault exists, the air bag indicator will flash the LFC five times, then it will remain illuminated for the rest of the key cycle. The RCM will also communicate the current and historical DTCs through the DLC, to the scan tool. If the air bag indicator does not function, and the system detects a fault condition, the RCM will signal the GEM to activate an audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed. After that fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors determine that a deployment is required. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation Air Bag Control Module: Service and Repair Removal and Installation REMOVAL WARNING: ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION IN WHICH THE RIGHT COWL A-PILLAR AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the right hand cowl side trim panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1258 3. Disconnect the Restraints Control Module (RCM). 1 Slide the two RCM electrical connector locking clips down to disengage them. 2 While squeezing the locking clip area to pivot the latch, disconnect the two RCM electrical connectors. 4. Remove the RCM with bracket. 1 Remove the three RCM bracket retaining bolts. 2 Remove the RCM with bracket. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1259 1. Follow the removal procedure in reverse order. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: A repair is made by installing a new part only. If the part does not correct the condition, install the original part and perform the diagnostic procedure again. 2. Prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1260 Air Bag Control Module: Service and Repair Weld Nut Repair "J" Nut WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both procedures before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J" nuts as outlined in this procedure. Weld nuts must be installed as outlined in Weld Nut Repair- Missing Weld Nut, Restraints Control Module (RCM), Front External Crash and Side Crash Sensor. ^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is in close proximity to the missing weld nut. 1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part numbers: N623342-S101, N800854-S100, N800925-S100). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190) or equivalent. 3. Install the "J" nut through the rectangular hole in the sheet metal. 4. Install the crash sensor. NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet metal. 5. Tighten the attaching screws to specification. Stripped Weld Nut WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455-S190). 2. Drill out the internal threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification. Missing Weld Nut WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1261 LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both procedures before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J", nuts as outlined in Weld Nut Repair "J" Nut, Restraints Control Module (RCM), Front External Crash and Side Crash Sensor. Weld nuts must be installed as outlined in this procedure. ^ Radiator support repair shown, others are similar. 1. Obtain a 6 mm (0.24 in) weld nut (part number N806285-S190). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-5190). 3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back out an adjacent access hole. 4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5. Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the copper welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole, firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld nut in position. 8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the edge of the weld nut. 9. Metal finish as required. 10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws to specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Warning Relay > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation Seat Belt Warning Relay: Technical Service Bulletins Seat Belts - Warning System Operation Article No. 01-2-5 2/05/01 ^ TRIM - SEAT BELT WARNING SYSTEM - "BELT ^ MINDER" FUNCTION - OPERATION AND SERVICE ^ TIPS ^ ELECTRICAL - SEAT BELT WARNING SYSTEM ^ "BELT MINDER" FUNCTION - OPERATION AND ^ SERVICE TIPS FORD: 2000-2001 CROWN VICTORIA, MUSTANG, TAURUS, EXCURSION, EXPEDITION, F-150, RANGER, WINDSTAR 2001 EXPLORER LINCOLN: 2000-2001 CONTINENTAL, TOWN CAR 2001 LS 2000-2001 NAVIGATOR MERCURY: 2000-2001 GRAND MARQUIS, SABLE 2001 MOUNTAINEER ISSUE The above vehicles have a "Belt Minder" feature that is supplemental to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning light on the instrument cluster. ACTION Some customers may wish to have the Belt Minder deactivated or reactivated. This can be done by performing the deactivation procedure in the Owner Guide (section on Safety Restraints, Belt Minder) or by using the Worldwide Diagnostic System (WDS) tool and performing the following Service Procedure. SERVICE PROCEDURE To deactivate or reactivate the Belt Minder using the WDS tool, refer to the following procedure. 1. Establish a session for the vehicle. 2. Select the "Toolbox" icon. 3. Select "Module Programming" and press the "Tick" mark. 4. Select "Programmable Parameters", then "Warning Lamps/Chimes" and press the "Tick" mark. 5. Select "Beltminder - (HEC)", then select "Enabled or Disabled" and press the "Tick" mark. 6. WDS will display "Configuration Complete", then press the "Tick" mark. NOTE: IF THE DRIVER'S SAFETY BELT IS NOT BUCKLED BEFORE THE VEHICLE HAS REACHED AT LEAST 5 KM/H (3 MPH) AND 1-2 MINUTES HAVE ELAPSED SINCE THE IGNITION SWITCH HAS BEEN TURNED ON, THEN THE BELT MINDER WILL ILLUMINATE THE SAFETY BELT WARNING LIGHT AND WILL SOUND THE SAFETY BELT WARNING CHIME FOR 6 SECONDS EVERY 30 SECONDS, REPEATING FOR APPROXIMATELY 5 MINUTES OR UNTIL THE SAFETY BELT IS BUCKLED. NOTE: WHEN THE BELT MINDER IS DEACTIVATED, THE SAFETY BELT WARNING LIGHT AND CHIME WILL CONTINUE TO OPERATE NORMALLY. THE SAFETY BELT WARNING LIGHT WILL REMAIN ILLUMINATED FOR 1-2 MINUTES AND THE WARNING CHIME WILL SOUND FOR 4-8 SECONDS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Warning Relay > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation > Page 1266 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 104000, 204000, 206000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1271 Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1272 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1273 Starter Relay: Service Precautions WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1274 Starter Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 1275 Starter Relay: Service and Repair REMOVAL WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE. 1. Disconnect the battery ground cable. 2. Disconnect the starter motor solenoid relay switch wiring. 1 Remove the protective cover. 2 Disconnect the push-on electrical connector. 3 Remove the nuts. 4 Remove the cable. 3. Remove the starter motor solenoid relay switch. 1 Remove the engine sensor/generator wires. 2 Remove the bolts and ground wire. 3 Remove the starter motor solenoid relay switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 1281 Compressor/Pump Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Specifications Suspension Control Module: Specifications Air Suspension Control Module Mounting Screws 18 - 27 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Specifications > Page 1285 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Specifications > Page 1286 Suspension Control Module: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Specifications > Page 1287 Suspension Control Module: Service and Repair Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Note: Ride heights must be reset for the air suspension module whenever the air suspension module is replaced. Disconnect the battery negative ground cable. 2. Remove the center instrument panel finish panel. 1 Remove the center instrument panel finish panel screws. 2 Disconnect the electrical connectors and remove the center panel finish panel. 3. Remove the air suspension control module. 1 Remove the air suspension control module screws. 2 Slide the air suspension control module down and out of the support bracket. 4. Disconnect the air suspension control module electrical connectors and remove the air suspension control module. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Specifications > Page 1288 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Note: When installing a new air suspension control module, ride height adjustment must be performed. Ride Height Adjustments To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair Control Module: Service and Repair Removal 1. Remove the transmission control switch (TCS). 1. Remove the TCS cover. 2. Remove the TCS. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 1298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 1299 Heated Glass Element Relay: Testing and Inspection Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 1300 Schematic Use 73III Automotive Meter to check for the continuity between terminal 85 and all other terminals. If resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 86 and 30 directly to the positive battery terminal. Use 73III Automotive Meter set in the volts position to check for voltage at terminal 87A. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 85, and ground the jumper wire to a known good ground. Check for voltage at terminal 87. If battery voltage is not indicated, replace the relay. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions Power Window Control Module: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1306 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1307 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1308 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1309 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1310 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1311 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1312 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1313 Power Window Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1314 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1315 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1316 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1317 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1318 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1319 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Page 1320 Power Window Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Page 1321 Power Window Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Page 1322 Power Window Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 1326 Power Window Relay: Description and Operation LH Front Window Regulator Control Switch Inputs Table The GEM controls manual down and OTD window movement with the OTD relay. The relay is activated by applying ground directly to one side of the down window relay coil, and is deactivated by removing the ground signal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 1327 Power Window Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Control Module: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1334 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1335 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1336 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1337 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1338 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1339 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1340 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1341 Windshield Washer Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1342 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1343 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1344 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1345 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1346 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1347 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Page 1348 Windshield Washer Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Page 1349 Windshield Washer Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Page 1350 Windshield Washer Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay > Page 1355 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 1356 Windshield Washer Relay: Testing and Inspection Testing an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper wires and 73 Digital Multimeter. Remove the relay to be tested from the power distribution box, fuse junction panel or individual connector. Terminals Component Testing Procedure Schematic Micro ISO Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 1357 Use the multimeter to check for the continuity between terminal 2 and all other terminals. If the resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 1 and 3 directly to the positive battery terminal. Use the multimeter set in the volts position to check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 2 and ground the jumper wire to a known good ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions Wiper Control Module: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1363 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1364 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1365 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1366 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1367 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1368 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1369 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1370 Wiper Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1371 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1372 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1373 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1374 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1375 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1376 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Page 1377 Wiper Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Page 1378 Wiper Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Page 1379 Wiper Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up Relay Wiper Relay: Locations Rear Wiper Up Relay Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up Relay > Page 1384 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up Relay > Page 1385 Wiper Relay: Locations Rear Wiper Down Relay Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up Relay > Page 1386 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up Relay > Page 1387 Wiper Relay: Locations Wiper High Relay Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up Relay > Page 1388 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up Relay > Page 1389 Wiper Relay: Locations Wiper Low Relay Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up Relay > Page 1390 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up Relay > Page 1391 Wiper Relay: Locations Wiper Park Relay Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up Relay > Page 1392 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 1393 Wiper Relay: Testing and Inspection Testing an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper wires and 73 Digital Multimeter. Remove the relay to be tested from the power distribution box, fuse junction panel or individual connector. Terminals Component Testing Procedure Schematic Micro ISO Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 1394 Use the multimeter to check for the continuity between terminal 2 and all other terminals. If the resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 1 and 3 directly to the positive battery terminal. Use the multimeter set in the volts position to check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 2 and ground the jumper wire to a known good ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock Cylinder Arm/Disarm Switch: Service and Repair Switch -Door Disarm, Front Door Lock Cylinder REMOVAL 1. Remove the driver door trim panel. 3. Remove the door disarm switch. 1 Remove the "E" clip. 2 Remove the lock rod actuator. 3 Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: The door disarm switch locator mark must be positioned towards the harness side of the switch prior to installation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock Cylinder > Page 1401 Arm/Disarm Switch: Service and Repair Switch-Door Disarm, Liftgate Lock Cylinder REMOVAL 1. Remove the liftgate trim panel. 2. Remove the watershield. 3. Remove the liftgate lock cylinder disarm switch. 1 Remove the "E" clip. 2 Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ The liftgate lock cylinder disarm switch locator mark must be positioned towards the harness side of the switch prior to installation. ^ Depress the liftgate lock cylinder to install the liftgate lock cylinder disarm switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock Cylinder Lock Cylinder Switch: Service and Repair Switch -Door Disarm, Front Door Lock Cylinder REMOVAL 1. Remove the driver door trim panel. 3. Remove the door disarm switch. 1 Remove the "E" clip. 2 Remove the lock rod actuator. 3 Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: The door disarm switch locator mark must be positioned towards the harness side of the switch prior to installation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock Cylinder > Page 1406 Lock Cylinder Switch: Service and Repair Switch-Door Disarm, Liftgate Lock Cylinder REMOVAL 1. Remove the liftgate trim panel. 2. Remove the watershield. 3. Remove the liftgate lock cylinder disarm switch. 1 Remove the "E" clip. 2 Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ The liftgate lock cylinder disarm switch locator mark must be positioned towards the harness side of the switch prior to installation. ^ Depress the liftgate lock cylinder to install the liftgate lock cylinder disarm switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings Parking Assist Distance Sensor: Customer Interest Parking Assist System - False Warnings TSB 05-4-18 03/07/05 FALSE PARKING AID WARNINGS FORD: 1999-2001 Explorer, Windstar 2000-2001 Excursion, Expedition 2001 F-Super Duty LINCOLN: 2000-2001 Navigator MERCURY: 1999-2001 Mountaineer This article supersedes TSB 04-26-2 to update the vehicle lines and model years. ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This condition may also occur on vehicles equipped with the forward sensing system (FSS) when vehicle is in reverse or drive. ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before replacing any sensor(s). SERVICE TIPS NOTE THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS. OPERATION AND COMMON CAUSE OF WARNINGS The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the FSS the system is operational when the vehicle is in reverse or drive. The FSS and RSS give an audible warning to the driver when obstacles are within 6' (1.8 meters) from the vehicle, and when obstacles are within 18" (46 cm) on either side of the bumper. NOTE CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS COMPOSED OF. NOTE THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE EXCEPTION STATED IN THE NOTE ABOVE. NOTE THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT ADJUSTABLE. In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or give warnings for 3 seconds then ceases, the occurrence may be due to any of the following reasons: BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE: Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 1415 Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is contaminated with any foreign material the system may sound a continuous tone or intermittent tone. The sensor surface can be cleaned by a high pressure water spray. SIDE COVERAGE SENSOR: There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large, extending obstacle such as a garage wall. If there is no encroachment between any of the outer sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the obstacle begin to move closer to each other, then the warning will begin again. Obstacles within 10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal operation. ABNORMAL ROAD SURFACES: The RSS/FSS may give warnings due to certain road surfaces with surface projections such as rocks, broken pavement, unplowed snow covered roads. This is considered normal operation. OTHER POSSIBLE CAUSES: Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External ultrasonic noise may be detected (high velocity air, machinery). This is considered normal operation. SENSOR DIAGNOSTICS 1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and within 6' (1.8 meters) of the front of the vehicle for the FSS. 2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high pressure water wash to ensure that the membrane gap is free of any dirt or contamination. 3. Using the New Generation Star (NGS) tester or WDS, observe the following four (4) parking aid module parameter identification displays (PIDs) for distance information: ^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle) ^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle) ^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle) ^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle) NOTE PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED. a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches (NGS+ and WDS). b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation procedures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 1416 ACCESSING PIDS WITH NGS, SELECT: ^ Vehicle Line ^ Diagnostic Data Link ^ PAM ^ PID/Data Monitor And Record ^ Select the appropriate PIDS ^ Start ACCESSING PIDS WITH WDS, START VEHICLE SESSION THEN SELECT: ^ Toolbox Icon ^ Datalogger, Then Tick (Check Mark) ^ Modules, Then Tick ^ PAM, Then Tick ^ Select The Appropriate PIDS, Then Tick WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 15K859 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings Parking Assist Distance Sensor: All Technical Service Bulletins Parking Assist System - False Warnings TSB 05-4-18 03/07/05 FALSE PARKING AID WARNINGS FORD: 1999-2001 Explorer, Windstar 2000-2001 Excursion, Expedition 2001 F-Super Duty LINCOLN: 2000-2001 Navigator MERCURY: 1999-2001 Mountaineer This article supersedes TSB 04-26-2 to update the vehicle lines and model years. ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This condition may also occur on vehicles equipped with the forward sensing system (FSS) when vehicle is in reverse or drive. ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before replacing any sensor(s). SERVICE TIPS NOTE THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS. OPERATION AND COMMON CAUSE OF WARNINGS The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the FSS the system is operational when the vehicle is in reverse or drive. The FSS and RSS give an audible warning to the driver when obstacles are within 6' (1.8 meters) from the vehicle, and when obstacles are within 18" (46 cm) on either side of the bumper. NOTE CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS COMPOSED OF. NOTE THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE EXCEPTION STATED IN THE NOTE ABOVE. NOTE THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT ADJUSTABLE. In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or give warnings for 3 seconds then ceases, the occurrence may be due to any of the following reasons: BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE: Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 1422 Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is contaminated with any foreign material the system may sound a continuous tone or intermittent tone. The sensor surface can be cleaned by a high pressure water spray. SIDE COVERAGE SENSOR: There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large, extending obstacle such as a garage wall. If there is no encroachment between any of the outer sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the obstacle begin to move closer to each other, then the warning will begin again. Obstacles within 10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal operation. ABNORMAL ROAD SURFACES: The RSS/FSS may give warnings due to certain road surfaces with surface projections such as rocks, broken pavement, unplowed snow covered roads. This is considered normal operation. OTHER POSSIBLE CAUSES: Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External ultrasonic noise may be detected (high velocity air, machinery). This is considered normal operation. SENSOR DIAGNOSTICS 1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and within 6' (1.8 meters) of the front of the vehicle for the FSS. 2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high pressure water wash to ensure that the membrane gap is free of any dirt or contamination. 3. Using the New Generation Star (NGS) tester or WDS, observe the following four (4) parking aid module parameter identification displays (PIDs) for distance information: ^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle) ^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle) ^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle) ^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle) NOTE PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED. a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches (NGS+ and WDS). b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation procedures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 1423 ACCESSING PIDS WITH NGS, SELECT: ^ Vehicle Line ^ Diagnostic Data Link ^ PAM ^ PID/Data Monitor And Record ^ Select the appropriate PIDS ^ Start ACCESSING PIDS WITH WDS, START VEHICLE SESSION THEN SELECT: ^ Toolbox Icon ^ Datalogger, Then Tick (Check Mark) ^ Modules, Then Tick ^ PAM, Then Tick ^ Select The Appropriate PIDS, Then Tick WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 15K859 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 1424 Parking Assist Distance Sensor: Specifications Azimuth System Check Object Position 1 (P1) and Position 5 (P5), Distance From Sensor 90 cm Azimuth System Check Object Position 2 (P2), 3 (P3) and Position 4 (P4), Distance From Sensor 160 cm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 1425 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 1426 Parking Assist Distance Sensor: Service and Repair REMOVAL 1. Remove the rear bumper. 2. Remove the parking aid sensor. 1 Disconnect the electrical connector. 2 Release the tabs. 3 Remove the parking aid sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Diagrams > Page 1430 Parking Assist Switch: Service and Repair REMOVAL 1. Remove the audio unit. For additional information, refer to Radio, Stereo, and Compact Disc. 2. Remove the center instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connector. 3. Remove the hood latch release handle. 1 Remove the screws. 2 Remove the hood latch release handle. 4. Remove the instrument panel lower steering column cover. 1 Remove the screws. 2 Remove the instrument panel lower steering column cover. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Diagrams > Page 1431 5. Remove the instrument panel steering column opening cover reinforcement. 1 Remove the screws. 2 Remove the instrument panel steering column opening cover reinforcement. 6. If equipped, position the column gearshift lever aside. 7. Remove the instrument cluster finish panel. 1 Remove the screws. 2 Remove the instrument cluster finish panel. ^ Disconnect the electrical connector. 8. Remove the parking aid switch. 1 Remove the screws. 2 Remove the parking aid switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair Remote Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the steering wheel controls. 1 Carefully remove the steering wheel controls. 2 Disconnect the steering wheel controls. NOTE: The steering wheel is leather wrapped and should be protected when removing the steering wheel controls. INSTALLATION 1. Install the steering wheel controls. 1 Connect the steering wheel controls. 2 Install the steering wheel controls. 2. Connect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 SOHC VIN K SFI (2001)) 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 1441 OASIS CODES: 201000, 201200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch 4 Door Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch > Page 1446 Power Door Lock Switch: Diagrams Power Door Lock Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front Power Door Lock Switch: Testing and Inspection Left Front Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 1449 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 1450 Power Door Lock Switch: Testing and Inspection Right Front Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 1451 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 1455 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 1456 Power Mirror Switch: Testing and Inspection Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 1457 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Left Power Seat Switch: Diagrams Left Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Left > Page 1462 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service Precautions > Technician Safety Information Power Seat Switch: Technician Safety Information WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service Precautions > Technician Safety Information > Page 1465 Power Seat Switch: Vehicle Damage Warnings CAUTION: - To prevent damage to the side shield, the clips must be depressed in order to release the side shield from the cushion pan. - Use care when disconnecting the seat cushion side shield from the seat cushion frame so the tabs on the seat cushion side shield are not damaged. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Memory Set Switch Power Seat Switch: Testing and Inspection Seat Memory Set Switch Remove the memory set switch. Measure the resistance between the indicated terminals while pressing the requested switches. The resistance should be less than 5 ohms for each switch position. If the resistance is not less than 5 ohms for each switch, replace the switch; otherwise, return to the calling Pinpoint Test. To check the memory set switch LED, connect the positive meter lead to terminal 8 and the negative lead to terminal 9. The meter should indicate greater than 0.3 volts. Reversing the leads, the meter should read OL. If the meter readings are not as indicated above, replace the switch; otherwise, return to the calling Pinpoint Test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Memory Set Switch > Page 1468 Power Seat Switch: Testing and Inspection Seat Regulator Control Switch Remove the seat regulator control switch. Measure the resistance between the indicated terminals while pressing the requested switches. The resistance should be less than 5 ohms for each switch position. If the resistance is not less than 5 ohms for each switch, replace the switch; otherwise, return to the calling Pinpoint Test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Sport Bucket Power Seat Switch: Service and Repair Sport Bucket REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, 3. Remove the lumbar support knob. 4. Remove the rear side shield screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Sport Bucket > Page 1471 5. Release the side shield clips. CAUTION: To prevent damage to the side shield, the clips must be depressed in order to release the side shield from the cushion pan. 6. Unhook the side shield from the seat latch. 7. If equipped, disconnect the heated seat switch electrical connector. 8. Remove the side shield. 1 Disconnect the electrical connector. 2 Remove the side shield. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Sport Bucket > Page 1472 9. Remove the 6-way power seat switch. 1 Remove the screws. 2 Remove the 6-way power seat switch. INSTALLATION WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 1. To install, reverse the removal procedure. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Sport Bucket > Page 1473 Power Seat Switch: Service and Repair Limited REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal and Installation. 3. Disconnect the power seat switch electrical connector. 4. Remove the front seat cushion side shield rear screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Sport Bucket > Page 1474 5. Remove the front seat cushion side shield screws. 6. Disconnect the front seat cushion side shield. CAUTION: Use care when disconnecting the seat cushion side shield from the seat cushion frame so the tabs on the seat cushion side shield are not damaged. 7. Disconnect the lumbar support control switch electrical connector. 8. Disconnect the lumbar support adjusting hoses from the adjusting switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Sport Bucket > Page 1475 9. If equipped, disconnect the heated seat switch electrical connector. 10. Remove the front seat cushion side shield. 11. Remove the 6-way power seat switch. 1 Remove the screws. 2 Remove the 6-way power seat switch. INSTALLATION 1. To install, reverse the removal procedure. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Left Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Left > Page 1480 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Sport Bucket Seat Heater Switch: Service and Repair Sport Bucket REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal and Installation. 3. Remove the lumbar support knob. 4. Remove the rear side shield screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Sport Bucket > Page 1483 5. Release the side shield clips. 6. Disconnect the heated seat switch electrical connector. 7. Remove the heated seat switch. INSTALLATION 1. To install, reverse the removal procedure. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Sport Bucket > Page 1484 Seat Heater Switch: Service and Repair Limited REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat Systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal and Installation. 3. Disconnect the power seat switch electrical connector. 4. Remove the front seat cushion side shield rear screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Sport Bucket > Page 1485 5. Remove the front seat cushion side shield screws. 6. Disconnect the front seat cushion side shield. CAUTION: Use care when disconnecting the seat cushion side shield from the seat cushion frame so the tabs on the seat cushion side shield are not damaged. 7. Disconnect the lumbar support control switch electrical connector. 8. Disconnect the lumbar support adjusting hoses from the adjusting switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Sport Bucket > Page 1486 9. Disconnect the heated seat switch electrical connector. 10. Remove the front seat cushion side shield. 11. Remove the heated seat switch. INSTALLATION 1. To install, reverse the removal procedure. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Page 1496 Trunk / Liftgate Switch: Testing and Inspection Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Page 1497 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 1502 Brake Fluid Level Sensor/Switch: Description and Operation The brake master cylinder fluid level warning switch is an integral part of the brake master cylinder reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the brake master cylinder reservoir. When the brake fluid in the brake master cylinder reservoir gets to a predetermined level, the floating magnet actuates the reed switch, causing the red brake warning indicator to illuminate. Loss of brake fluid will cause this system to activate. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Specifications Brake Fluid Pressure Sensor/Switch: Specifications Brake pressure switch 11-14 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Differential Speed Sensor > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Specifications Parking Brake Release Switch: Specifications Parking brake remote release to instrument panel ......................................................................................................................... 2.1-2.9 Nm (19-25 ft. lbs) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Front anti-lock brake sensor bolt (4x2) 71 - 88 ft.lb Front anti-lock brake sensor wire retaining bolt (4x4) 62 - 80 ft.lb Front anti-lock brake sensor bolt (4x4) 62 - 80 ft.lb Rear anti-lock brake sensor bolt 20 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left Front Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left Front > Page 1517 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front Wheel Speed Sensor: Service and Repair Sensor, Front Removal 1. Raise and support the vehicle. 2. Disconnect the front anti-lock brake sensor wire from the vehicle frame. 1 Disconnect the electrical connector. 2 Unclip the front anti-lock brake sensor wire from the vehicle frame. 3. Remove the front anti-lock brake sensor. 1 Remove the bolt. 2 Remove the front ant1 -lock brake sensor. Installation 1. NOTE: Plug the sensor mount opening and thoroughly clean the mounting surface. Apply High Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A meeting Ford specification ESA-M1Cl98-A. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 1520 Wheel Speed Sensor: Service and Repair Sensor, Rear Removal 1. Raise and support vehicle. 2. NOTE: Clean off dirt and debris that may have collected around the rear anti-lock brake sensor before removal. Remove the rear anti-lock brake sensor. 1 Disconnect the rear anti-lock brake sensor electrical connector. 2 Remove the bolt. 3 Remove the rear anti-lock brake sensor. Installation 1. NOTE: Thoroughly clean the mounting surface. NOTE: Inspect the anti-lock brake sensor O-ring for damage; lightly lubricate the O-ring with High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 15 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 1526 Coolant Temperature Sensor/Switch (For Computer): Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 1527 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 1528 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Remove the thermostat and housing. For additional information, refer to Cooling System. 2. Disconnect the battery ground cable. For additional information, refer to Battery. 3. Remove the Engine Coolant Temperature (ECT) sensor. 1 Disconnect the connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor CYLINDER HEAD TEMPERATURE SENSOR Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy details. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor > Page 1533 Engine Temperature Sensor: Description and Operation Engine Coolant Temperature (ECT) Sensor ENGINE COOLANT TEMPERATURE (ECT) SENSOR Engine Coolant Temperature (ECT) Sensor The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Engine coolant temperature (ECT) sensor 89 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications > Page 1537 Temperature Sensor (Gauge): Description and Operation When the engine temperature is low, the resistance of the water temperature indicator sender unit is high, thus restricting the flow of current through the gauge and moving the pointer only a short distance. As the temperature of the coolant increases, the resistance decreases, allowing more current to flow through the gauge and results in a corresponding movement of the pointer. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Brake Switch (Cruise Control): Recalls Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1551 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1552 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1553 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1554 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1555 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1556 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1557 Attachment III - Technical Information Table of Contents Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1558 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1559 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1560 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1561 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1562 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1563 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1564 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1565 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1566 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1567 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1568 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1569 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1570 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1571 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1572 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1573 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1574 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1575 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1576 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 1581 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Brake Switch (Cruise Control): All Technical Service Bulletins Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1591 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1592 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1593 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1594 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1595 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1596 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1597 Attachment III - Technical Information Table of Contents Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1598 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1599 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1600 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1601 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1602 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1603 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1604 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1605 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1606 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1607 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1608 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1609 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1610 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1611 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1612 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1613 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1614 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1615 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1616 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): All Technical Service Bulletins Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 1621 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 1622 Brake Switch (Cruise Control): Specifications Deactivator Switch 15-20 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Technician Safety Information Brake Switch (Cruise Control): Technician Safety Information WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Technician Safety Information > Page 1625 Brake Switch (Cruise Control): Vehicle Damage Warnings 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. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Page 1626 Brake Switch (Cruise Control): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the deactivator switch electrical connector. 3. Remove the deactivator switch. WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES 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: 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. INSTALLATION 1. To install, reverse the removal procedure. NOTE ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. ^ After the deactivator switch is installed, it is necessary to bleed the brake system; refer to Brakes. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating Technical Service Bulletin # 09S09 Date: 091013 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1635 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on October 13, 2009. NOTE: This recall pertains to certain vehicles that have a factory installed speed control deactivation switch only. Ford offered a Genuine Accessory Speed Control kit that utilized a production steering wheel identical to the factory-installed system. The Ford accessory kit does not use a master cylinder mounted deactivation switch and, as a result, vehicles with this kit are not included in this recall. If a customer inquires about Safety Recall 09509, and the VIN of their vehicle is not listed in OASIS under 09509, the vehicle is not involved in the program. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by October 15, 2009. Owner names and addresses will be available by December 18, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1636 RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Ford Motor Company is offering a refund for owner paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ Refunds will only be provided for the cost associated with repairs due to a leaking speed control deactivation switch. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 09S09 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. ^ Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim. If a repair is performed on the same visit, the repair and refunds should be submitted on separate repair lines. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. ^ Claiming information for Electrical Grease II for servicing both the speed control servo and SCDS adapter jumper harness connector - applies to Labor Operation 09509G or 09S09H. (Submit on same repair line as repair.) - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $6.30 ^ Claiming information for Electrical Grease II for servicing SCDS adapter jumper harness connector only - applies to Labor Operation 09509D, 09509F or 09509J (Submit on same repair line as repair.) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1637 - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $0.50 Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1638 PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this safety recall is 50409. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Affected speed control deactivation switches and related damage parts are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1639 TABLE OF CONTENTS OVERVIEW This Safety Recall involves an inspection of the Speed Control Deactivation Switch (SCDS) harness connector for the presence of brake fluid contamination. If no brake fluid is present, install the universal fused jumper harness. If brake fluid is present, replace the SCDS and inspect the speed control servo harness connector for heat damage. See Flow Chart # 2. In addition, for 1999 through 2003 Windstar vehicles, the repair includes an inspection of the Anti-lock Brake System (ABS) connectors. See Flow Chart # 2. If a related damage condition is found that you believe to be caused by a leaking SCDS, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. REPAIR FLOW CHARTS Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1640 Flow Chart # 1 shows the repair procedure for all affected vehicles except 1999 through 2003 Windstar vehicles. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1641 Flow Chart # 2 shows the repair procedure for 1999 through 2003 Windstar vehicles. SCDS Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1642 The Speed Control Deactivation Switch (SCDS) involved in Safety Recall 09S09 and the revised SCDS are illustrated (See Figure 1). Note that the revised SCDS has a different electrical connector An adapter jumper harness (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS SCDS Location In most vehicles involved in this recall, the SCDS is located on the master cylinder. In 1992-1993 E-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail under the driver's seat. In 1993 F-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail below the master cylinder To verify, just follow the metal brake lines from the master cylinder until the switch is found On F-53 Motorhome vehicles, if the SCDS is not located on the master cylinder, it maybe located in a brake line junction block approximately 457 mm (18 in) below the master cylinder It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. SCDS INSPECTION PROCEDURE NOTE: For E-Series vehicles, there is a possibility that the vehicle was manufactured without a SCDS If unable to locate a SCDS after checking on all the brake lines, no further action is required, release the vehicle NOTE: On 1992-1993 E-Series and 1993 F-Series vehicles, it may be necessary to lift the vehicle to gain access to the SCDS On Windstar vehicles, the air cleaner housing must be separated in the middle to gain access to the SCDS Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1643 1. Disconnect the harness connector from the SCDS (See Figure 2) 2. Inspect the harness connector for the presence of brake fluid. ^ If there is no evidence of brake fluid on the connector, install Universal Fused Jumper Harness (UFJH). ^ If there is evidence of brake fluid on the connector, replace SCDS. UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION 1. Connect the Universal Fused Jumper Harness (UFJH) to the SCDS and the vehicle harness. 2. Secure the UFJH to the existing harness with tie straps making sure the fuse holders are positioned vertically with the fuse holder cap facing upward Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1644 Wrap the tie straps underneath then over the top of the existing harness and verify proper fuse holder orientation (See Figure 3). 3. No further action is required release the vehicle. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and if necessary fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS (See Figure 4). NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed 3. Remove the old SCDS. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft). 5. Check the brake fluid level at the master cylinder fill to maximum fluid level and install the brake fluid reservoir cap. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1645 6. Before installing the adapter jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II (XG-15-A) (See Figure 5). 7. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the adapter jumper harness to a nearby component such as the speed control cable or another wire harness. ^ If the vehicle has a speed control servo, proceed with speed control servo inspection. ^ If the vehicle is a 1999-2003 Windstar that does not have speed control, proceed with ABS inspection. ^ If none of the above apply, no further action is required, release the vehicle. SPEED CONTROL SERVO INSPECTION 1. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage (See Figure 6) ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector) proceed to step 2 for further instructions. ^ If heat damage is found proceed as follows: - 1999-2003 Windstar complete ABS inspection before calling the Special Service Support Center for further instructions. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1646 - All other vehicles call the Special Service Support Center for further instructions. 2. With the speed control servo disconnected use shop air to blow out any trace of brake fluid from the speed control servo harness electrical connector and the servo module. Do not use any type of solvent to clean the connectors. 3. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II (XG-15-A) across the entire width and length of the servo vehicle harness connector (See Figure 7). NOTICE: Be sure to apply an adequate amount of grease to the vehicle harness connector only DO NOT apply the grease directly to the connector of the servo module. 4. Reconnect the harness to the servo module. 5. If the vehicle is a 1999-2OO3 Windstar proceed to ABS inspection. Otherwise no further action is required, release the vehicle. ANTI-LOCK BRAKE SYSTEM (ABS) INSPECTION NOTE: This inspection applies to 1999 through 2003 Windstar vehicles only. 1. Lift vehicle and remove ABS cover. 2. Disconnect ABS module. Inspect the ABS harness and module connectors for the presence of brake fluid. 3. If brake fluid is present use shop air to blow out any trace of brake fluid from the harness connector and module. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1647 4. Inspect the ABS harness and module connectors for corrosion and/or heat damage (See Figure 8). 5. If evidence of corrosion and/or heat damage is found in either the ABS harness or module connector call the Special Service Support Center for further instructions. 6. If there is no evidence of corrosion and/or heat damage reconnect the ABS harness to the ABS module. 7. Is the speed control servo heat damaged? ^ If the speed control servo is heat damaged call the Special Service Support Center for further instructions. ^ If the speed control servo is not heat damaged no further action is required release the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1648 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1649 Owner Letter Owner Letter not available at this time. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating Technical Service Bulletin # 09S09 Date: 091013 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1655 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on October 13, 2009. NOTE: This recall pertains to certain vehicles that have a factory installed speed control deactivation switch only. Ford offered a Genuine Accessory Speed Control kit that utilized a production steering wheel identical to the factory-installed system. The Ford accessory kit does not use a master cylinder mounted deactivation switch and, as a result, vehicles with this kit are not included in this recall. If a customer inquires about Safety Recall 09509, and the VIN of their vehicle is not listed in OASIS under 09509, the vehicle is not involved in the program. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by October 15, 2009. Owner names and addresses will be available by December 18, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1656 RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Ford Motor Company is offering a refund for owner paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ Refunds will only be provided for the cost associated with repairs due to a leaking speed control deactivation switch. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 09S09 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. ^ Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim. If a repair is performed on the same visit, the repair and refunds should be submitted on separate repair lines. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. ^ Claiming information for Electrical Grease II for servicing both the speed control servo and SCDS adapter jumper harness connector - applies to Labor Operation 09509G or 09S09H. (Submit on same repair line as repair.) - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $6.30 ^ Claiming information for Electrical Grease II for servicing SCDS adapter jumper harness connector only - applies to Labor Operation 09509D, 09509F or 09509J (Submit on same repair line as repair.) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1657 - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $0.50 Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1658 PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this safety recall is 50409. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Affected speed control deactivation switches and related damage parts are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1659 TABLE OF CONTENTS OVERVIEW This Safety Recall involves an inspection of the Speed Control Deactivation Switch (SCDS) harness connector for the presence of brake fluid contamination. If no brake fluid is present, install the universal fused jumper harness. If brake fluid is present, replace the SCDS and inspect the speed control servo harness connector for heat damage. See Flow Chart # 2. In addition, for 1999 through 2003 Windstar vehicles, the repair includes an inspection of the Anti-lock Brake System (ABS) connectors. See Flow Chart # 2. If a related damage condition is found that you believe to be caused by a leaking SCDS, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. REPAIR FLOW CHARTS Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1660 Flow Chart # 1 shows the repair procedure for all affected vehicles except 1999 through 2003 Windstar vehicles. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1661 Flow Chart # 2 shows the repair procedure for 1999 through 2003 Windstar vehicles. SCDS Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1662 The Speed Control Deactivation Switch (SCDS) involved in Safety Recall 09S09 and the revised SCDS are illustrated (See Figure 1). Note that the revised SCDS has a different electrical connector An adapter jumper harness (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS SCDS Location In most vehicles involved in this recall, the SCDS is located on the master cylinder. In 1992-1993 E-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail under the driver's seat. In 1993 F-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail below the master cylinder To verify, just follow the metal brake lines from the master cylinder until the switch is found On F-53 Motorhome vehicles, if the SCDS is not located on the master cylinder, it maybe located in a brake line junction block approximately 457 mm (18 in) below the master cylinder It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. SCDS INSPECTION PROCEDURE NOTE: For E-Series vehicles, there is a possibility that the vehicle was manufactured without a SCDS If unable to locate a SCDS after checking on all the brake lines, no further action is required, release the vehicle NOTE: On 1992-1993 E-Series and 1993 F-Series vehicles, it may be necessary to lift the vehicle to gain access to the SCDS On Windstar vehicles, the air cleaner housing must be separated in the middle to gain access to the SCDS Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1663 1. Disconnect the harness connector from the SCDS (See Figure 2) 2. Inspect the harness connector for the presence of brake fluid. ^ If there is no evidence of brake fluid on the connector, install Universal Fused Jumper Harness (UFJH). ^ If there is evidence of brake fluid on the connector, replace SCDS. UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION 1. Connect the Universal Fused Jumper Harness (UFJH) to the SCDS and the vehicle harness. 2. Secure the UFJH to the existing harness with tie straps making sure the fuse holders are positioned vertically with the fuse holder cap facing upward Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1664 Wrap the tie straps underneath then over the top of the existing harness and verify proper fuse holder orientation (See Figure 3). 3. No further action is required release the vehicle. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and if necessary fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS (See Figure 4). NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed 3. Remove the old SCDS. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft). 5. Check the brake fluid level at the master cylinder fill to maximum fluid level and install the brake fluid reservoir cap. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1665 6. Before installing the adapter jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II (XG-15-A) (See Figure 5). 7. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the adapter jumper harness to a nearby component such as the speed control cable or another wire harness. ^ If the vehicle has a speed control servo, proceed with speed control servo inspection. ^ If the vehicle is a 1999-2003 Windstar that does not have speed control, proceed with ABS inspection. ^ If none of the above apply, no further action is required, release the vehicle. SPEED CONTROL SERVO INSPECTION 1. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage (See Figure 6) ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector) proceed to step 2 for further instructions. ^ If heat damage is found proceed as follows: - 1999-2003 Windstar complete ABS inspection before calling the Special Service Support Center for further instructions. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1666 - All other vehicles call the Special Service Support Center for further instructions. 2. With the speed control servo disconnected use shop air to blow out any trace of brake fluid from the speed control servo harness electrical connector and the servo module. Do not use any type of solvent to clean the connectors. 3. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II (XG-15-A) across the entire width and length of the servo vehicle harness connector (See Figure 7). NOTICE: Be sure to apply an adequate amount of grease to the vehicle harness connector only DO NOT apply the grease directly to the connector of the servo module. 4. Reconnect the harness to the servo module. 5. If the vehicle is a 1999-2OO3 Windstar proceed to ABS inspection. Otherwise no further action is required, release the vehicle. ANTI-LOCK BRAKE SYSTEM (ABS) INSPECTION NOTE: This inspection applies to 1999 through 2003 Windstar vehicles only. 1. Lift vehicle and remove ABS cover. 2. Disconnect ABS module. Inspect the ABS harness and module connectors for the presence of brake fluid. 3. If brake fluid is present use shop air to blow out any trace of brake fluid from the harness connector and module. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1667 4. Inspect the ABS harness and module connectors for corrosion and/or heat damage (See Figure 8). 5. If evidence of corrosion and/or heat damage is found in either the ABS harness or module connector call the Special Service Support Center for further instructions. 6. If there is no evidence of corrosion and/or heat damage reconnect the ABS harness to the ABS module. 7. Is the speed control servo heat damaged? ^ If the speed control servo is heat damaged call the Special Service Support Center for further instructions. ^ If the speed control servo is not heat damaged no further action is required release the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1668 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1669 Owner Letter Owner Letter not available at this time. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Recalls for Cruise Control Switch: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Cruise Control Switch: Recalls Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Cruise Control Switch: All Technical Service Bulletins Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 1683 Cruise Control Switch: Specifications Speed Control Actuator Switch Screws 6.5-7.5 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 1684 Cruise Control Switch: Service Precautions CAUTION: When separating the speed control actuator switch from the steering wheel, it is necessary to take precautions not to damage the steering wheel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Without Remote Audio Cruise Control Switch: Service and Repair Without Remote Audio REMOVAL 1. Remove the driver side air bag module. Refer to Air Bag Systems. 2. Remove the speed control actuator switches. 1 Remove the screws. 2 Disconnect the electrical connector then remove the speed control actuator switches. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16km (10 miles) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Without Remote Audio > Page 1687 Cruise Control Switch: Service and Repair With Remote Audio REMOVAL 1. Disconnect the battery ground cable. 2. Separate the speed control actuator switch out of the steering wheel. CAUTION: When separating the speed control actuator switch from the steering wheel, it is necessary to take precautions not to damage the steering wheel. 3. Remove the speed control actuator switch. 1 Disconnect the speed control actuator switch electrical connector. 2 Remove the speed control actuator switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn its strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil pressure sensor 9-11 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 1692 Oil Pressure Sender: Description and Operation The oil pressure switch is installed in the engine block and consists of a diaphragm and contact points. The contact points are closed with oil pressure causing the gauge to indicate NORMAL oil pressure. With no oil pressure, the contacts open and the gauge indicates low oil pressure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 1693 Oil Pressure Sender: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Additional information may also be found at Engine; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 1694 Oil Pressure Sender: Service and Repair Removal and Installation 1. Discard the battery ground cable. 2. Disconnect the oil pressure sensor electrical connector and remove the sensor. 3. Note: Coat the threads of the oil pressure sensor with Pipe Sealant with Teflon D8AZ-19554-A or Wsk-M2G350-A2. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Service and Repair Air Conditioning Switch: Service and Repair REMOVAL 1. Remove the climate control assembly. 2. Remove the heater blower motor switch. 1 Remove the screw. 2 Rotate and remove the heater blower motor switch. NOTE: The knob will come off when the switch is removed. 3. Remove the temperature control switch and the A/C damper door switch. 1 Remove the screw. 2 Rotate and remove the temperature control switch. 3 Rotate and remove the A/C damper door switch. NOTE: The knobs will come off when the switch is removed. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 1702 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 1703 Ambient Temperature Sensor / Switch HVAC: Description and Operation The A/C ambient air temperature sensor and bracket: - is located in front of the A/C condenser core near the center of the vehicle. - contains a thermistor which measures the temperature of outside air as a resistance and sends that reading to the electronic automatic temperature control assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 1710 Cabin Temperature Sensor / Switch: Description and Operation The in-car temperature sensor operates in the following manner: - A thermistor in the in-car temperature sensor measures air temperature inside the passenger compartment. - An automatic temperature control sensor hose and elbow is connected between the plenum assembly and the in-car temperature sensor. - The automatic temperature control sensor hose and elbow takes air from the plenum assembly air stream to create a suction in the in-car temperature sensor. - The suction draws in-vehicle air into the in-car temperature sensor and across the thermistor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications Refrigerant Pressure Sensor / Switch: Specifications A/C Cycling Switch 324 kPa Close Minimum A/C Cycling Switch 152 kPa Open Minimum Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 1714 Refrigerant Pressure Sensor / Switch: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 1715 Manual A/C Electrical Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 1716 Electronic Automatic Temperature Control Electrical Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 1717 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch Refrigerant Pressure Sensor / Switch: Description and Operation A/C Cycling Switch A/C Cycling Switch The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction accumulator/drier. - A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. - This allows the suction pressure inside the suction accumulator/drier to control the operation of the A/C cycling switch. - The electrical switch contacts open when the suction pressure drops to 152-193 kPa (22-28 psi). - The contacts close when the suction pressure rises to 276-324 kPa (40-47 psi). - When the A/C cycling switch contacts close, the signal to energize the A/C clutch is sent to the wide open throttle A/C cutoff relay. - When the A/C cycling switch contacts open, the A/C clutch field coil is de-energized and compressor operation stops. - The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. - This prevents icing of the A/C evaporator core and blockage of airflow. - It is not necessary to discharge the refrigerant system to remove the A/C cycling switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 1720 Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning Cycling Switch PCM Inputs AIR CONDITIONING CYCLING SWITCH The Air Conditioning (A/C) cycling switch may be wired to either the A/C Cycling Switch (ACCS) or ACPSW Powertrain Control Module (PCM) input. When the A/C cycling switch opens, the PCM will turn off the Air Conditioning (A/C) clutch For information on the specific function of the A/C cycling switch, refer to Heating and Air Conditioning. The A/C Cycling Switch (ACCS) circuit to the PCM provides a voltage signal which indicates when the A/C is requested. When the A/C demand switch is turned on, and both the A/C cycling switch and the high pressure contacts of the A/C high pressure switch (if equipped and in circuit) are closed, voltage is supplied to the ACCS circuit at the PCM. Refer to Vehicle/Diagrams for vehicle specific wiring. If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate. For additional information, refer to PCM outputs, wide open throttle air conditioning cutoff. See: Powertrain Management/Description and Operation/PCM Outputs NOTE: Some applications do not have a dedicated (separate) input to the PCM indicating that A/C is requested. This information is received by the PCM through the BUS + and BUS - Standard Corporate Protocol (SCP) communication. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 1721 Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning High Pressure Switch Typical Air Conditioning Pressure Sensor The A/C pressure cut-off switch is used to interrupt A/C compressor operation in the event of high system discharge pressures. - The A/C pressure cut-off switch is mounted on a Schrader valve-type fitting on the high pressure side of the A/C manifold and tube. - A valve depressor, located inside the threaded end of the A/C pressure cut-off switch, presses on the Schrader valve stem. - This allows the A/C pressure cut-off switch to monitor the compressor discharge pressure. - When the compressor discharge pressure rises to approximately 2,896 kPa (420 psi), the switch contacts open, disengaging the A/C compressor. - When the pressure drops to approximately 1,724 kPa (250 psi), the contacts close to allow operation of the A/C compressor. - It is not necessary to discharge the refrigerant system to remove the A/C pressure cut-off switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations Solar Sensor: Locations Electronic Automatic Temperature Control Electrical Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 1725 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 1726 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 1727 Solar Sensor: Description and Operation The A/C sunload sensor: - is located on the top side of the instrument panel. - contains a photovoltaic diode that is sensitive to light. - has some unspecified resistance across the terminals depending upon the amount of light reaching the photovoltaic diode; therefore the only test that can be performed is for an internal short circuit. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the upper and lower steering column shrouds. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair > Page 1732 5. Remove the multi-function switch. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 1736 Door Switch: Service and Repair REMOVAL 1. Remove the door trim panel. 2. Remove the door latch. For additional information, refer to Door Latch. 3. Remove the door opening warning lamp switch. 1 Lift the locking tab. 2 Rotate the door opening warning lamp switch counterclockwise. 3 Remove the door opening warning lamp switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection Fuel Gauge Sender: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Page 1740 Fuel Gauge Sender: Service and Repair Service and Repair For further information regarding this component please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Service and Repair Key Reminder Switch: Service and Repair For further information regarding the service of this component and the system that it is part of, please refer to Instrument Panel, Gauges and Warning indicators; Service and Repair; Warning Devices. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations > Page 1747 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 1752 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Specifications Backup Lamp Switch: Specifications Backup Lamp Switch 25-35 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Specifications > Page 1756 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Specifications > Page 1757 Backup Lamp Switch: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Specifications > Page 1758 Backup Lamp Switch: Service and Repair REMOVAL 1. Raise and support the vehicle; refer to Maintenance/Service and Repair. 2. Disconnect the backup lamp switch electrical connector. 3. Remove the backup lamp switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Locations Exterior Lighting System Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Locations > Page 1762 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Locations > Page 1763 Brake Pedal Position Switch: Description and Operation BRAKE PEDAL POSITION SWITCH Typical Brake Pedal Position Switch The Brake Pedal Position (BPP) switch (Figure 21) is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality. On most applications the BPP switch is hard wired to the PCM and supplies battery positive voltage (B+) when the vehicle brake pedal is applied. On other applications the BPP switch signal is broadcast over the SCP link via another module to be received by the PCM. On applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stop amp bulbs has failed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Locations > Page 1764 Brake Pedal Position Switch: Service and Repair REMOVAL 1. Disconnect the brake pedal position (BPP) switch connector. 2. Remove the BPP switch 1 Remove the self-locking pin. 2 Remove the spacer. 3 Remove the BPP switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection Combination Switch: Testing and Inspection For further information regarding this component please refer to Turn Signal Switch; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection > Page 1768 Combination Switch: Service and Repair For further information regarding this component please refer to Turn Signal Switch; Service and Repair. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 1772 Door Switch: Service and Repair REMOVAL 1. Remove the door trim panel. 2. Remove the door latch. For additional information, refer to Door Latch. 3. Remove the door opening warning lamp switch. 1 Lift the locking tab. 2 Rotate the door opening warning lamp switch counterclockwise. 3 Remove the door opening warning lamp switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Specifications Fog/Driving Lamp Switch: Specifications Fog Lamp Switch Mounting Bezel Screws 2-3 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Specifications > Page 1776 Exterior Lighting System Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Specifications > Page 1777 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Specifications > Page 1778 Fog/Driving Lamp Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. 3 Disconnect the electrical connectors. 3. Remove the fog lamp switch. 1 Remove the screws. 2 Remove the mounting bezel. 3 Release the two tabs and remove the fog lamp switch. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Specifications > Page 1779 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 1783 Hazard Warning Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 1784 Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 1785 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 1786 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams Headlamp Dimmer Switch: Diagrams For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 1790 Headlamp Dimmer Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 1791 Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 1792 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 1793 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Specifications Headlamp Switch: Specifications Head Lamp Switch Screws 2-3 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Specifications > Page 1797 Exterior Lighting System Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1800 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1801 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1802 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1803 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1804 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1805 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1806 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1807 Headlamp Switch: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1808 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1809 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1810 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1811 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1812 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1813 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1814 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 1815 Headlamp Switch: Testing and Inspection Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 1816 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 1817 Headlamp Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel steering column opening cover reinforcement; refer to Dashboard. 3. Remove the center instrument panel finish panel. 1 Remove the screws. 2 Remove the instrument panel finish panel. 4. Remove the instrument cluster finish panel. 1 Remove the screws. 2 Remove the cluster instrument panel finish panel. 5. Disconnect the headlamp switch electrical connectors and remove the headlamp switch knob. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 1818 6. Remove the headlamp switch. 1 Remove the screws. 2 Remove the headlamp switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation Horn Switch: Description and Operation The horn blow switches are underneath the driver side air bag module in the steering wheel. The switches are powered through the air bag sliding contact and ground through the steering column. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation > Page 1822 Horn Switch: Service and Repair REMOVAL 1. Remove the driver side air bag; refer to Air Bag Systems. 2. Remove the switches. 1 Disconnect the horn wire (BK) from the switches. 2 Remove the attaching bolts from the switches and remove the switches. INSTALLATION 1. To install, reverse the removal procedure. ^ Prove out the air bag system; refer to Air Bag Systems. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Service and Repair Interior Light Switch: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the interior lamp switch. 1 Disconnect the interior lamp switch electrical connector. 2 Remove the interior lamp switch. ^ Push inward; rotate counterclockwise. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Turn Signal Switch: Diagrams For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1829 Turn Signal Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1830 Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1831 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1832 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1833 Turn Signal Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the upper and lower steering column shrouds. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1834 5. Remove the multi-function switch. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 SOHC VIN K SFI (2001)) 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 1839 OASIS CODES: 201000, 201200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Description and Operation Absolute Pressure Sensor: Description and Operation THERMAL MANIFOLD ABSOLUTE PRESSURE SENSOR Thermal Manifold Absolute Pressure (TMAP) Sensor The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 41) consists of a Manifold Absolute Pressure (MAP) sensor and an integrated thermistor. The thermistor part of the sensor is currently not being used. The MAP part of the sensor measures intake manifold air absolute pressure. The PCM uses information from the MAP sensor, Throttle Position (TP) sensor, Mass Air Flow (MAF) sensor, Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CKP) sensor and Crankshaft Position (CKP) sensor to determine how much exhaust gas is introduced into the intake manifold. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications Mass Air Flow Sensor: Specifications Mass Air Flow Sensor Nuts And Bolts 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 1848 Mass Air Flow Sensor: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 1849 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 1850 Mass Air Flow Sensor: Description and Operation MASS AIR FLOW SENSOR Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 1851 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Loosen the air cleaner outlet tube clamp and position aside. 4. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor, Stud Bolt 19 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1855 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1856 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1857 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the CMP sensor electrical connector. 2 Remove the CMP sensor stud bolt. 3 Remove the camshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams > Page 1861 Clutch Switch: Description and Operation CLUTCH PEDAL POSITION SWITCH Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch (Figure 24) is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference Vehicle Reference Voltage (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 15 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 1865 Coolant Temperature Sensor/Switch (For Computer): Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 1866 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 1867 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Remove the thermostat and housing. For additional information, refer to Cooling System. 2. Disconnect the battery ground cable. For additional information, refer to Battery. 3. Remove the Engine Coolant Temperature (ECT) sensor. 1 Disconnect the connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolts 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 1871 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Electronic Engine Controls Crankshaft Position Sensor: Description and Operation Electronic Engine Controls The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Electronic Engine Controls > Page 1874 Crankshaft Position Sensor: Description and Operation Standard Models (Non BI-Fuel) CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference (Figure 25). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Page 1875 Crankshaft Position Sensor: Service and Repair REMOVAL NOTE: The 5.0L is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Crankshaft Position (CKP) sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ 4.0L SOHC and 4.0L (push rod) CKP sensors need to be touching the damper. The CKP sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure sensor wiring is routed away from the battery cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor CYLINDER HEAD TEMPERATURE SENSOR Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy details. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor > Page 1880 Engine Temperature Sensor: Description and Operation Engine Coolant Temperature (ECT) Sensor ENGINE COOLANT TEMPERATURE (ECT) SENSOR Engine Coolant Temperature (ECT) Sensor The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation The fuel sending unit is a variable resistor made up of a ceramic substrate. It is controlled by the action of a float arm. When the fuel level is low, resistance in the unit is low. When the fuel level is high, the resistance is high. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 1887 Fuel Tank Pressure Sensor: Service Precautions CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 1888 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The Fuel Tank Pressure (FTP) sensor (Figure 97) or inline Fuel Tank Pressure (FTP) sensor (Figure 98) is used to measure the fuel tank pressure during the EVAP monitor test on vehicles equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank pressure by forcing the system to purge. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 1889 Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Remove the fuel tank. For additional information, refer to Fuel Delivery and Air Induction. 2. Remove the fuel tank pressure sensor. 1 Disconnect the electrical connector. 2 Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the fuel tank. CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. INSTALLATION 1. To install, reverse removal procedure. ^ Leak test the evaporative emission system. For additional information, refer to Evaporative Emission System Leak Test System. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emissions repair verification drive cycle. For additional information, refer to Evaporative Emission Repair Verification Drive Cycle. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Service and Repair Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation Intake Air Temperature Sensor: Description and Operation INTAKE AIR TEMPERATURE SENSOR Intake Air Temperature (IAT) Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire Terminals The Intake Air Temperature (IAT) sensors (Figure 34) and integrated Mass Air Flow (MAF) type (Figure 37), are thermistor devices in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Page 1893 Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel spark and MAF. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Supercharged 5.4L Lightning vehicles use (2) AT sensors. Both sensors operate as above. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor Second Intake Air Temperature (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Bolt 25 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 1897 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 1898 Knock Sensor: Description and Operation Knock Sensor Two Types Of Knock Sensor (KS) The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 1899 Knock Sensor: Service and Repair REMOVAL 1. Remove the lower in take manifold. For additional information, refer to Engine. 2. Remove the knock sensor. 1 Remove the bolt. 2 Remove the knock sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1904 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1905 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1906 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1907 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1908 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1909 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1910 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1911 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1912 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1913 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1914 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1915 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1916 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1917 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1918 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Page 1919 Heated Oxygen Sensor: Specifications Heated Oxygen Sensor 41 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations > Oxygen Sensor Bank Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations > Oxygen Sensor Bank Locations > Page 1922 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated Oxygen 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1925 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1926 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1927 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1928 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1929 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1930 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1931 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1932 Heated Oxygen Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1933 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1934 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1935 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1936 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1937 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1938 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1939 Heated Oxygen Sensor: Connector Views Ford does not provide connector views for this vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 1940 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Heated Oxygen Sensor (HO2S) Monitor Heated Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S) Monitor Heated Oxygen Sensor Monitor The Heated Oxygen Sensor (HO2S) Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration which can affect emissions. The fuel control or upstream HO2S is checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S used for Catalyst Monitor are also monitored for proper output voltage. The following illustration shows that input is required from the Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CHT), Intake Air Temperature (IAT), Mass Air Flow (MAF) and Crankshaft Position (CKP) sensors to activate the HO2S Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. 1. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. The HO2S Monitor evaluates both the upstream (fuel control) and downstream (Catalyst Monitor) HO2S for proper function. 2. Once the HO2S Monitor is enabled, the upstream HO2S signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. A HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the Output State Monitor (OSM) and by measuring the current going through the heater circuit. The HO2S Monitor DTCs can be categorized as follows: The Diagnostic Trouble Code (DTCs) associated with HO2S lack of switching are DTCs P1130, P1131, P1132, P1150, P1151 and P1152. The DTCs associated with HO2S slow response rate are DTCs P0133 and P0153. The DTCs associated with HO2S signal circuit malfunction are DTCs P0131, P0136, P0148, P0151 and P0156. The DTCs associated with a HO2S heater circuit malfunction are DTCs P0135, P0141, P0155 and P0161. The Diagnostic Trouble Code (DTC) associated with the downstream HO2S not running in on-demand is DTC P1127. The DTCs associated with swapped HO2S connectors are DTCs P1128 and P1129. 3. The Malfunction Indicator Lamp (MIL) is activated after a fault is detected on two consecutive drive cycles. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Heated Oxygen Sensor (HO2S) Monitor > Page 1943 Heated Oxygen Sensor: Description and Operation PCM Inputs HEATED OXYGEN SENSOR Heated Oxygen Sensor (HO2S) The Heated Oxygen Sensor (HO2S) (Figure 33) detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop operation. The Vehicle Power (VPWR) circuit supplies voltage to the heater and the PCM will complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater and heater control system are installed on some vehicles. The high power heater reaches closed loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 1944 Heated Oxygen Sensor: Service and Repair EGO Sensor Wrench SPECIAL SERVICE TOOL(S) REMOVAL NOTE: The 5.0L RH is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar. 1. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 2. Remove the bolts and the skid plate. 3. Remove the Three Way Catalytic Converter (TWC). For additional information, refer to Catalytic Converter. 4. Using the special tool, remove the HO2S. NOTE: If necessary, lubricate the HO2S with Penetrating and Lock Lubricant E8AZ-19A501-B or equivalent to assist in removal. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply a light coat of High Temperature Nickel Anti-Sieze Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A to the threads of the HO2S. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 1945 Syncro Positioning Tool Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of 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). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1954 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1955 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1956 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1957 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1958 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of 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). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1964 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1965 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1966 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1967 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 1968 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1973 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1974 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1975 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1981 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1982 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 1983 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 1984 Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR Bolts 8 - 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 1985 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 1986 Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 1987 Tube Mounted Differential Pressure Feedback EGR Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 1988 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the differential pressure feedback EGR electrical connector. 3. Disconnect the differential pressure feedback EGR hoses. 4. Remove the bolts and the differential pressure feedback EGR. INSTALLATION 1. Fit the differential pressure feedback EGR and loosely install the bolts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 1989 2. Tighten the bolts. 3. Connect the differential pressure feedback EGR hoses. 4. Connect the differential pressure feedback EGR electrical connector. 5. Connect the battery ground cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1993 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs Throttle Position Sensor: Description and Operation PCM Inputs THROTTLE POSITION SENSOR Typical Throttle Position (TP) Sensor The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs > Page 1996 Throttle Position Sensor: Description and Operation Intake Air Systems THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the On-Board Diagnostic (OBD) II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page 1997 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the accelerator control snow shield. 3. Remove the Throttle Position (TP) sensor. 1 Disconnect the TP sensor electrical connector. 2 Remove the sensor. NOTE: The 4.0L (SOHC) is shown, the 4.0L push rod is similar. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital transmission range (TR) sensor screws 71 - 97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2001 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2002 Digital Transmission Range Sensor: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2003 Digital Transmission Range Sensor: Service and Repair Special Tools Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the shift cable. 1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the bracket. 4. Disconnect the digital transmission range (TR) sensor electrical connector. 5. Remove the manual control outer lever nut and manual control outer lever. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2004 6. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor. 1. Position the digital TR sensor. 2. Loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Note: The manual lever must he in the neutral position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever. 1. Install the manual control outer lever. 2. Install the manual control outer lever nut. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2005 4. Connect the digital transmission range (TR) sensor electrical connector. 5. Connect the shift cable. 1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. Connect the battery ground cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Vehicle Speed Sensor Bolt 98 - 115 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2011 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2012 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2013 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2014 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2015 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2016 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2017 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2018 Vehicle Speed Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2019 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2020 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2021 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2022 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2023 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2024 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2025 Diagram 64-1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2026 Vehicle Speed Sensor: Description and Operation VEHICLE SPEED SENSOR Typical Vehicle Speed Sensor (VSS) The Vehicle Speed Sensor (VSS) (Figure 45) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling and torque converter clutch scheduling. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of 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). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2036 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2037 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2038 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2039 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2040 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of 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). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2046 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2047 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2048 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2049 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2050 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 2055 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 2056 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 2057 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 2063 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 2064 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 2065 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 2066 Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR Bolts 8 - 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 2067 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 2068 Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 2069 Tube Mounted Differential Pressure Feedback EGR Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 2070 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the differential pressure feedback EGR electrical connector. 3. Disconnect the differential pressure feedback EGR hoses. 4. Remove the bolts and the differential pressure feedback EGR. INSTALLATION 1. Fit the differential pressure feedback EGR and loosely install the bolts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 2071 2. Tighten the bolts. 3. Connect the differential pressure feedback EGR hoses. 4. Connect the differential pressure feedback EGR electrical connector. 5. Connect the battery ground cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications Mass Air Flow Sensor: Specifications Mass Air Flow Sensor Nuts And Bolts 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 2076 Mass Air Flow Sensor: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 2077 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 2078 Mass Air Flow Sensor: Description and Operation MASS AIR FLOW SENSOR Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 2079 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Loosen the air cleaner outlet tube clamp and position aside. 4. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation Fuel Pressure Sensor/Switch: Description and Operation FUEL RAIL PRESSURE SENSOR Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor (Figure 31) is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor (Figure 32) senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 2086 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch (Figure 72) is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner Guide for the location of the IFS. Inertia Fuel Shutoff (IFS) Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 2087 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Disconnect the battery. For additional information, refer to Battery. 2. Access the Inertia Fuel Shutoff (IFS) switch on the RH toe board and disconnect the electrical connector. 3. Remove the bolts and remove the IFS switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2091 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs Throttle Position Sensor: Description and Operation PCM Inputs THROTTLE POSITION SENSOR Typical Throttle Position (TP) Sensor The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs > Page 2094 Throttle Position Sensor: Description and Operation Intake Air Systems THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the On-Board Diagnostic (OBD) II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 2095 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the accelerator control snow shield. 3. Remove the Throttle Position (TP) sensor. 1 Disconnect the TP sensor electrical connector. 2 Remove the sensor. NOTE: The 4.0L (SOHC) is shown, the 4.0L push rod is similar. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor, Stud Bolt 19 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2100 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2101 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2102 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the CMP sensor electrical connector. 2 Remove the CMP sensor stud bolt. 3 Remove the camshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolts 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2106 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Electronic Engine Controls Crankshaft Position Sensor: Description and Operation Electronic Engine Controls The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Electronic Engine Controls > Page 2109 Crankshaft Position Sensor: Description and Operation Standard Models (Non BI-Fuel) CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference (Figure 25). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Page 2110 Crankshaft Position Sensor: Service and Repair REMOVAL NOTE: The 5.0L is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Crankshaft Position (CKP) sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ 4.0L SOHC and 4.0L (push rod) CKP sensors need to be touching the damper. The CKP sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure sensor wiring is routed away from the battery cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. 2. Prove out the air bag system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 2116 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 2117 4. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. Installation WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 2118 WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Note: Use a new ignition switch lock cylinder. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. 2. Prove out the air bag system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Bolt 25 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 2122 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 2123 Knock Sensor: Description and Operation Knock Sensor Two Types Of Knock Sensor (KS) The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 2124 Knock Sensor: Service and Repair REMOVAL 1. Remove the lower in take manifold. For additional information, refer to Engine. 2. Remove the knock sensor. 1 Remove the bolt. 2 Remove the knock sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Side Crash Sensor 12 Nm Front Crash Sensor 10.2-13.8 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Driver Side Air Bag Crash Sensor Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Driver Side Air Bag Crash Sensor > Page 2131 Impact Sensor: Locations Front Crash Sensors Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Driver Side Air Bag Crash Sensor > Page 2132 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Driver Side Air Bag Crash Sensor > Page 2133 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Driver Side Air Bag Crash Sensor > Page 2134 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front External Crash Sensor Impact Sensor: Service and Repair Front External Crash Sensor REMOVAL WARNING: ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: A repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the radiator grill and radiator opening cover. 3. Remove the air bag sensor. 1 Disconnect the air bag sensor electrical connector. 2 Remove the three screws. 3 Remove the air bag sensor. INSTALLATION WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: A repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front External Crash Sensor > Page 2137 1. Follow the removal procedure in reverse order. 2. Prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front External Crash Sensor > Page 2138 Impact Sensor: Service and Repair Side Crash Sensor REMOVAL WARNING: ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. ^ Right side is shown, left side is similar. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the B-pillar lower trim panel with scuff plates. NOTE: ^ Four door is shown, two door is similar. ^ The front seat has been removed for clarity. 3. Remove the side crash sensor. 1 Disconnect the side crash sensor electrical connector. 2 Remove the two retaining bolts. 3 Remove the side crash sensor with bracket. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front External Crash Sensor > Page 2139 WARNING: ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Follow the removal procedure in reverse order. 2. Prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. 2. Prove out the air bag system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 2149 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 2150 4. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. Installation WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 2151 WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Note: Use a new ignition switch lock cylinder. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. 2. Prove out the air bag system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 2155 Neutral Safety Switch: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Page 2162 Ride Height Sensor: Service and Repair Removal WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing of an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Remove the spare tire 3. Disconnect the height sensor electrical connector and remove the electrical connector harness from the frame and apron to separate the push-in fasteners 4. Release the upper and lower spring clip and pull the sensor from the ball studs. Installation 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Service and Repair Suspension Mode Switch: Service and Repair Removal 1. Remove the jack storage access cover. 2. Remove the retaining screw and air suspension switch bracket. 3. Remove the air suspension switch. 1 Disconnect the electrical connector. 2 Press the retaining clips and remove the air suspension switch from the bracket. Installation 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital transmission range (TR) sensor screws 71 - 97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2174 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2175 Digital Transmission Range Sensor: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2176 Digital Transmission Range Sensor: Service and Repair Special Tools Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the shift cable. 1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the bracket. 4. Disconnect the digital transmission range (TR) sensor electrical connector. 5. Remove the manual control outer lever nut and manual control outer lever. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2177 6. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor. 1. Position the digital TR sensor. 2. Loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Note: The manual lever must he in the neutral position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever. 1. Install the manual control outer lever. 2. Install the manual control outer lever nut. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2178 4. Connect the digital transmission range (TR) sensor electrical connector. 5. Connect the shift cable. 1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. Connect the battery ground cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Turbine shaft speed (TSS) sensor screw 71 - 97 in.lb Output shaft speed sensor (OSS) sensor screw 71 - 97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 2182 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Speed 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2185 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2186 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2187 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2188 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2189 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2190 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2191 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2192 Transmission Speed Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2193 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2194 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2195 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2196 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2197 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2198 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2199 Transmission Speed Sensor: Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2200 Diagram 29-4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 2201 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Transfer Case Automatic Shift Transmission Speed Sensor: Service and Repair Transfer Case - Automatic Shift Output Shaft Speed Sensor-Front Removal 1. Remove the transfer case shift motor. 2. Remove the front output shaft speed sensor. 1. Remove the bolt. 2. Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Output Shaft Speed Sensor-Rear Removal Warning: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. 1. Raise and support vehicles. 2. Disconnect the electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Transfer Case Automatic Shift > Page 2204 3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector. 1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover. 4. Remove the bolt and the sensor. Installation 1. Caution: Make sure the sensor seats flat against the boss To install, reverse the removal procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Transfer Case Automatic Shift > Page 2205 Transmission Speed Sensor: Service and Repair 5R55E Removal 1. Raise and support the vehicle. 2. Disconnect output shaft speed (OSS) sensor electrical connector. 3. Remove OSS sensor. 1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission. - Inspect the OSS sensor O-ring for damage. If damaged, replace the O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Transfer Case Automatic Shift > Page 2206 2. Connect OSS sensor electrical connector. 3. Lower the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations The Transmission Fluid Temperature Sensor is located on the main control body wiring harness assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2212 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2213 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2214 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2215 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2216 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2217 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2218 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2219 Transmission Temperature Sensor/Switch: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2220 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2221 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2222 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2223 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2224 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2225 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2226 Diagram 29-4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 2227 Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference voltage signal. The resistance in the TFT varies with temperature. The powertrain control module (PCM) monitors the voltage signal across the TFT, and uses this information to determine the transmission fluid temperature. The TFT is located on the main control body wiring harness assembly. The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation and electronic pressure control (EPC). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Turbine shaft speed (TSS) sensor screw 71 - 97 in.lb Output shaft speed sensor (OSS) sensor screw 71 - 97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications > Page 2232 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > 4R70W Transmission Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > 4R70W Transmission > Page 2235 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 2236 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Transfer Case Automatic Shift Transmission Speed Sensor: Service and Repair Transfer Case - Automatic Shift Output Shaft Speed Sensor-Front Removal 1. Remove the transfer case shift motor. 2. Remove the front output shaft speed sensor. 1. Remove the bolt. 2. Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Output Shaft Speed Sensor-Rear Removal Warning: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. 1. Raise and support vehicles. 2. Disconnect the electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Transfer Case Automatic Shift > Page 2239 3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector. 1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover. 4. Remove the bolt and the sensor. Installation 1. Caution: Make sure the sensor seats flat against the boss To install, reverse the removal procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Transfer Case Automatic Shift > Page 2240 Transmission Speed Sensor: Service and Repair 5R55E Removal 1. Raise and support the vehicle. 2. Disconnect output shaft speed (OSS) sensor electrical connector. 3. Remove OSS sensor. 1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission. - Inspect the OSS sensor O-ring for damage. If damaged, replace the O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Transfer Case Automatic Shift > Page 2241 2. Connect OSS sensor electrical connector. 3. Lower the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Specifications Power Window Switch: Specifications Rear Window Regulator Switch Plate Screws 1.4-2.0 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch Power Window Switch: Diagrams Power Window Switch 2 Door Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 2251 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 2252 4 Door Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 2253 Power Window Switch: Description and Operation The window regulator control switch: ^ Is located on each door trim panel. ^ May be used to raise or lower both LH side and RH side windows from the master control on the driver door. ^ Includes a window lock feature that is controlled through the master control. ^ Can manually lower the driver side window when the master control is depressed longer than 0.4 seconds. ^ The driver side window can be completely lowered when the master control is depressed between 0.04 and 0.4 seconds and then released. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch Power Window Switch: Testing and Inspection Master Window Control Switch Component Testing Procedure Component Testing Procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 2256 Terminals Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 2257 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 2258 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 2259 Power Window Switch: Testing and Inspection Power window Switch Right Front Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 2260 Schematic Left Rear Component Testing Procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 2261 Terminals Schematic Right Rear Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 2262 Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 2263 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Driver Door Power Window Switch: Service and Repair Driver Door REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front door trim panel. 3. Remove the window regulator switch plate harness assembly. 1 Remove the screws. 2 Remove the harness assembly. 4. Remove the window regulator control switch. 1 Pry the release tabs. 2 Remove the window regulator control switch. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Driver Door > Page 2266 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Driver Door > Page 2267 Power Window Switch: Service and Repair Rear Door REMOVAL 1. Remove the rear window regulator switch plate. 1 Remove the screws. 2 Remove the rear window regulator switch plate. 2. Remove the window regulator switch plate harness assembly. 1 Remove the screws. 2 Remove the harness assembly. 3. Remove the window regulator control switch. 1 Pry the release tabs. 2 Remove the window regulator control switch. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Driver Door > Page 2268 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications Windshield Washer Switch: Specifications Windshield Wiper Washer Switch 2-3 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 2273 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Multifunction Switch Windshield Washer Switch: Diagrams Multifunction Switch For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Multifunction Switch > Page 2276 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 2277 Windshield Washer Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 2278 Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 2279 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 2280 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 2281 Windshield Washer Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the upper and lower steering column shrouds. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 2282 5. Remove the multi-function switch. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Rear Wiper And Washer System Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 2286 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Multifunction Switch Wiper Switch: Diagrams Multifunction Switch For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Multifunction Switch > Page 2289 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 2290 Wiper Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 2291 Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 2292 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 2293 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Rear Wiper Switch Wiper Switch: Service and Repair Rear Wiper Switch REMOVAL 1. Remove the instrument panel finish panel. 1 Remove the two screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 2. Remove the rear wiper/washer switch. 1 Remove the screws. 2 Remove the mounting bezel. 3 Release the two tabs and remove the rear wiper/washer switch. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Rear Wiper Switch > Page 2296 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Rear Wiper Switch > Page 2297 Wiper Switch: Service and Repair Multifunction Switch Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Rear Wiper Switch > Page 2298 2 Remove the upper and lower steering column shrouds. 5. Remove the multi-function switch. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Alignment Procedure Revision Alignment: Technical Service Bulletins Steering/Suspension - Alignment Procedure Revision TSB 04-24-19 12/13/04 REVISED PROCEDURE FOR ADJUSTING ALIGNMENT ON ALL SUSPENSIONS - NEW RIGHT HAND UPPER CONTROL ARM DESIGN FOR TORSION BAR FRONT SUSPENSIONS FORD: 1998-2001 Explorer 1998-2003 Ranger 2000-2003 Explorer Sport 2001-2003 Explorer Sport Trac ISSUE The cam bolt and nut kit that was used for adjusting caster and camber on all torsion bar and coil spring front suspensions has been discontinued. If the caster and camber settings need to be adjusted, a washer must now be installed. The right hand upper control arm design changed from a two piece design to a single piece design during the 2003 model year. The single piece design is now the only version of the upper control arm available for service of prior model year Rangers. ACTION Use the following Camber And Caster Adjustment procedure when either camber or caster need to be adjusted on any suspension, or if only a caster split adjustment is needed on a vehicle equipped with single piece upper control arm. Use the following Caster Split Adjustment - Two Piece Right Hand Upper Control Arm procedure if only a caster split adjustment is needed on a vehicle equipped with a two piece upper control arm. SERVICE PROCEDURE CAMBER AND CASTER ADJUSTMENT NOTE THE UPPER CONTROL ARM-TO-FRAME MOUNTING BOLTS HAVE SET SHIMS THAT MUST BE REPLACED WITH WASHERS TO ALLOW FOR ADJUSTMENT OF THE ARM IN THE FRAME SLOT. THE VEHICLE SHOULD BE SUPPORTED BY THE LOWER CONTROL ARM TO EASE MOVEMENT OF THE UPPER ARM IN THE SLOT. 1. Remove and discard the upper control arm-to-frame nuts and shims (Figure 1). 2. Install new washers (W705040-5900) and nuts (N805480-5427). Tighten the nuts so there is tension, but the upper control arm can be moved for the alignment adjustment. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Alignment Procedure Revision > Page 2304 3. To adjust caster and camber refer to the chart. Adjustments that require moving the front and rear of the upper control arm should be made equally. 4. Torque the upper control arm-to-frame nuts to 98 lb.ft (133 N.m). 5. Check and if necessary adjust the front toe. Refer to the appropriate Workshop Manual for information. CASTER SPLIT ADJUSTMENT - TWO PIECE RIGHT HAND UPPER CONTROL ARM 1. To decrease the right hand caster, loosen the ball joint adjustment nuts (Figure 2) and move the ball joint forward. 2. To increase the right hand caster, loosen the ball joint adjustment nuts and move the ball joint rearward. 3. Torque the ball joint adjustment nuts to 129 lb.ft (175 N.m). 4. Check and if necessary adjust the front toe. Refer to the appropriate Workshop Manual for information. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 3084 07 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 2305 Alignment: Specifications Caster LH 4.2 - 1.0 deg 0 deg. Frame Angle (If vehicle is higher in the rear, add the frame angle to the measured caster. If vehicle is lower in the rear, subtract the frame angle from the measured caster. Compare the total to the specification.) RH 4.2 - 1.0 deg Total/Split -0.7 +/- 0.5 deg Camber LH -0.5 +/- 0.5 deg RH -0.5 +/- 0.5 deg Total/Split 0 +/- 0.7 deg Toe 0.12 +/- 0.25 deg @ Curb Ride Height (positive value is toe-in, negative value is toe-out) Wheel Track 0.02 in Dogtracking 1.18 in maximum (centerline of front tires compared to centerline of rear tires) Clear Vision -2.4 +/- 3.0 deg (negative value is counterclockwise) Front Ride Height New Vehicles With less than 500 miles 4.4 +/- 0.4 in Original Parts 4.0 +/- 0.4 in Replacement Parts 4.4 +/- 0.1 in Rear Ride Height 4 Door Vehicles 5 - 5.8 in 2 Door Vehicles 4.3 - 4.8 in Ball Joint Radial Play Lower Ball Joint Maximum 1/32 in Upper Ball Joint Maximum 1/32 in Vehicle Lean Front Wheel Opening Maximum 0.6 in Side to Side Height Differences Rear Wheel Opening Maximum 0.78 in Torque Specifications Caster Set Jam Nuts 129 ft lb Front Suspension Upper Arm Cam Nuts 98 ft lb Toe Set Jam Nuts 59 ft lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber Alignment: Description and Operation Camber Negative and Positive Camber Negative and Positive Camber Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or negative and has a direct effect on tire wear. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 2308 Alignment: Description and Operation Caster Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the side. The caster specifications will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 2309 Alignment: Description and Operation Dogtracking Dogtracking Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of dogtracking. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 2310 Alignment: Description and Operation Drift/Pull Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep the vehicle going straight. Drift describes what a vehicle with this condition does with hands off the steering wheel. ^ A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead path and require constant steering input in the opposite direction to counteract the effect. ^ Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road camber). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 2311 Alignment: Description and Operation Camber Negative and Positive Camber Negative and Positive Camber Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or negative and has a direct effect on tire wear. Caster Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the side. The caster specifications will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear. Dogtracking Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 2312 Dogtracking Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of dogtracking. Drift/Pull Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep the vehicle going straight. Drift describes what a vehicle with this condition does with hands off the steering wheel. ^ A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead path and require constant steering input in the opposite direction to counteract the effect. ^ Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road camber). General Information Caster and camber are adjusted by means of eccentric cams on the upper control arm mounting bolts. Toe is adjusted by the use of the front wheel spindle tie-rod. Nibble Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road surfaces and observed by the driver as small rotational oscillations of the steering wheel. Poor Groove Feel Poor groove feel is characterized by little or no buildup of turning effort felt in the steering wheel as the wheel is rocked slowly left and right within very small turns around center or straight-ahead (under 20° of steering wheel turn). Efforts may be said to be "flat on center." ^ Under 20° of turn, most of the turning effort that builds up comes from the mesh of gear teeth in the steering gear. In this range, the steering wheel is not yet turned enough to feel the effort from the self-aligning forces at the road wheel or tire patch. ^ In the diagnosis of a readability problem, it is important to understand the difference between wander and poor groove feel. Poor Returnability/Sticky Steering Poor returnability and sticky steering is used to describe the poor return of the steering wheel to center after a turn or the steering correction is completed. Ride Height Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 2313 Front Ride Height Measurement Rear Ride Height Measurement Shimmy Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel resulting from large, side-to-side (lateral) tire/wheel movements. Shimmy is usually experienced near 64 km/h (40 mph), and can begin or be amplified when the tire contacts pot holes or irregularities in the road surface. Toe Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 2314 Positive Toe (Toe In) Positive Toe (Toe In) Negative Toe (Toe Out) Negative Toe (Toe Out) The vehicle toe setting: ^ affects tire wear and directional stability. ^ must be checked after adding aftermarket equipment, such as a snowplow or body. Wander Wander is the tendency of the vehicle to require frequent, random left and right steering wheel corrections to maintain a straight path down a level road. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment Alignment: Service and Repair Camber and Caster Adjustment 1. Remove the nuts and alignment plates. 2. Install the cams and the nuts. 3. Note: A pry bar can be used between the front suspension arm bushing joint and the frame pocket to aid in moving the farm. To increase the LF caster and camber, use the following steps. 1 To increase caster, move the front of the front suspension arm bushing joint outboard and move the rear of the front suspension arm bushing joint inboard. 2 To increase camber, move the front suspension arm bushing joint outboard equally. 4. To decrease the LF caster and camber, use the following steps. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2317 1 To decrease caster, move the front of the front suspension arm bushing joint inboard and move the rear of the front suspension arm bushing joint outboard. 2 To decrease camber, move the front suspension arm bushing joint inboard equally. 5. Tighten the nuts. 6. Note: A pry bar can be used between the front suspension arm bushing joint and the frame pocket to aid in moving the arm. To increase RF caster and camber, use the following steps. 1 To increase caster, move the front of the front suspension arm bushing joint outboard and move the rear of the front suspension arm bushing joint inboard. 2 To increase camber, move the front suspension arm bushing joint outboard equally. 7. To decrease the RF caster and camber, use the following steps. 1 To decrease caster, move the front of the front suspension arm bushing joint inboard and move the rear of the front suspension arm bushing joint outboard. 2 To decrease camber, move the front suspension arm bushing joint inboard equally. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2318 8. Increase the caster split. 1 Loosen the nuts. 2 Adjust the caster set bolts forward. 9. Decrease the caster split. 1 Loosen the nuts. 2 Adjust the caster set bolts rearward. 10. Tighten the nuts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2319 Alignment: Service and Repair Ride Height Ride Height - Front Suspension 1. Drive the vehicle onto a drive-on lift. 2. Jounce the vehicle's front and rear suspension to normalize the vehicle static ride height. 3. Measure the distance between the center line of the front suspension lower arm bushing bolt and the lift. Record the measurement. 4. Measure the distance between the front wheel spindle (lowest point) and the lift. Record the measurement. 5. Determine ride height. ^ Subtract measurement 1 from measurement 2. This is the ride height. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2320 6. Note: The torsion bar adjusting bolt is coated with adhesive that wears; off after disassembly. If the torsion bar system is ever disassembled or the torsion bar adjusting bolt is ever removed, use a new torsion bar adjusting bolt when re-assembling. Adjust the torsion bars (height) as necessary by tightening or loosening the torsion bar adjusting bolt. ^ Tighten the torsion bar adjusting bolt to increase the torque or raise the height. ^ Loosen the torsion bar adjusting bolt to decrease the torque or lower the height. Ride Height - Vehicle Dynamic Suspension Special Service Tool(s) 1. Connect scan tool to the Data Link Connector (DLC). 2. Select the RIDE CONTROL OUTPUT screen and turn on the following solenoids to vent the entire system of air and to lower the vehicle to its lowest attainable height: ^ REAR FILL (rear fill solenoid). ^ GATE VALVE (gate solenoid). ^ VENT (vent solenoid). 3. Close all doors including the liftgate and liftgate window. 4. Reopen any door (to ensure that the height will not change until the internal electronic calibration is complete). 5. Park the vehicle on a flat surface. 6. From the function menu, quickly select RIDE HEIGHT CALIBRATION. 7. Note the warning on the scan tool screen and follow the directions. 8. Lower the vehicle and clear all stored Diagnostic Trouble Codes (DTCs). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2321 Alignment: Service and Repair Toe Adjustment 1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering wheel in the "straight forward" position by attaching a rigid link from the steering wheel to the brake pedal. 3. Check the toe settings; follow the manufacturer's instructions. 4. Note: Do not allow the steering gear bellows to twist when the front wheel spindle tie-rod (3280) is rotated. Remove the clamps. 5. Loosen the nuts. ^ Clean and lubricate the nut(s) and front wheel spindle tie-rod threads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2322 6. Rotate the front wheel spindle tie-rods. 7. Tighten the nuts. 8. Install the clamps. 9. Recheck the toe settings; follow the manufacturer's instructions. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Fuel Pressure Relief Valve Bolts 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information Fuel Pressure Test Port: Technician Safety Information WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information > Page 2330 Fuel Pressure Test Port: Vehicle Damage Warnings CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 2331 Fuel Pressure Test Port: Description and Operation PRESSURE TEST POINT There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE TEST KIT #134-ROO87 OR EQUIVALENT. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 2332 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Remove the upper intake manifold. For additional information, refer to Engine. 2. Disconnect fuel supply line. 3. Remove the four bolts and the fuel supply line from the fuel supply manifold. 4. Remove the fuel supply line bracket bolt and the fuel supply line. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. NOTE: Lubricate the new O-ring seals with Super Premium SAE 5W-30 Motor Oil, XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G, to aid installation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > With 104 Pin Processor Idle Speed: Specifications With 104 Pin Processor Hot Idle ................................................................................................................................................ ......................................................... 670 - 750 RPM Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > With 104 Pin Processor > Page 2337 Idle Speed: Specifications With 150 Pin Processor With Automatic Transmission Hot Idle ................................................................................................................................................ .................................................................. 750 RPM With Manual Transmission Hot Idle ................................................................................................................................................ .................................................................. 750 RPM Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Service and Repair Air Cleaner Housing: Service and Repair REMOVAL 1. Disconnect the air cleaner assembly. ^ Loosen the clamp and disconnect the outlet tube. ^ Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the air cleaner assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR 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. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2345 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL SERVICE TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR 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. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and attach the Fuel Pressure Gauge. 2. Open the manual valve on the Fuel Pressure Gauge slowly and relieve the fuel pressure. NOTE: Open the manual valve slowly to relieve the system pressure. This may drain fuel from the system. Place the fuel in a suitable container. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2346 Fuel Pressure Gauge Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Coil Terminal-To-Cylinder Relationship Firing order........................................................................................................................................... ..................................................................1-4-2-5-3-6 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 2350 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service Precautions Ignition Cable: Service Precautions CAUTION: ^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. ^ Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service Precautions > Page 2358 Ignition Cable: Service and Repair Spark Plug Wire Remover SPECIAL SERVICE TOOL(S) REMOVAL CAUTION: ^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. 1. With a twisting motion, use the special tool to pull the spark plug wire off the spark plug. 2. Squeeze the locking tabs and twist while pulling upward to remove the spark plug wires from the ignition coil. 3. Remove the spark plug wires. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service Precautions > Page 2359 1. To install, reverse the removal procedure. CAUTION: Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. NOTE: Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to the inside of the spark plug and ignition coil boots of the spark plug wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark Plug Gap 1.3 - 1.4 mm RH Original Spark Plug AGRF22PG LH Original Spark Plug AGRF22P New Spark Plug (Either Side) AGSF22PP Spark Plugs 20 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 2364 Spark Plug: Specifications Spark Plug Gap 1.3 - 1.4 mm RH Original Spark Plug AGRF22PG LH Original Spark Plug AGRF22P New Spark Plug (Either Side) AGSF22PP Spark Plugs 20 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2365 Spark Plug: Application and ID RH Original Spark Plug Type .............................................................................................................. .............................................................. AGRF22PG LH Original Spark Plug Type ............................ .................................................................................................................................................... AGRF22P New Spark Plug Type (Either Side) ................................................................................... ................................................................................. AGSF22PP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2366 Spark Plug: Service and Repair REMOVAL 1. Remove the spark plug wires. For additional information, refer to Ignition Cable. 2. Remove the spark plugs. NOTE: ^ Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs. ^ If an original spark plug is reused, make sure it is installed in the same cylinder it was taken from. New spark plugs can be used in any cylinder. 3. Inspect the spark plugs. 4. Use a suitable spark plug gap tool to check and adjust the spark plug gap. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. For additional information, refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2370 Compression Check: Testing and Inspection 1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery is correctly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No.1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of Super Premium SAE 5W-30 Motor Oil, XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test-Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2371 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75 percent of the highest reading. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The 4.0L Push Rod engine has hydraulic lifters and requires no valve clearance adjustments. The 4.0L SOHC engine: - Manufacturer does not indicate whether the type of valve arrangement for this engine. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Locations > Page 2378 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Locations > Page 2379 Drive Belt: Description and Operation The accessory drive system consists of the following: drive belt - generator - power steering pump - A/C compressor - water pump pulley - drive belt tensioner - belt idler pulley - crankshaft pulley The accessory drive: has a single serpentine drive belt (six ribs). - has an automatic tensioner. - is not adjustable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Drive Belt: Initial Inspection and Diagnostic Overview 1. Verify the customer's concern by operating the engine to duplicate the condition. 2. Inspect to determine if any of the following mechanical concerns apply: 3. Inspect for drive belt cracking/chunking/wear. 4. If the concerns remain after inspection, determine the symptoms and go to the symptom chart. Under severe operating conditions (high temperature, low humidity), drive belt rib cracking can occur at less than 96,000 km (60,000 miles). Drive belt rib cracking (cracks across grooves): is not a reason for concern. - has no detrimental effect on drive belt performance. Cracks parallel to grooves are acceptable. The drive belt is still perfectly functional until rib chunking occurs. Drive belt chunking is where the rubber material actually chunks out between the cracks. The drive belt should be replaced if chunking occurs. V-Ribbed Belt With Cracks (Acceptable) V-Ribbed Belt With Chunks Of Rib Missing (Not Acceptable) 5. If the concern(s) remains after inspection, determine the symptoms and go to the Symptom Chart. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2382 Drive Belt: Symptom Related Diagnostic Procedures 1 of 2 2 of 2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2383 Drive Belt: Component Tests and General Diagnostics Belt Tensioner The automatic drive belt tensioner can be checked as follows: 1. With the engine running, observe the drive belt tensioner movement. The drive belt tensioner should move (respond) when the A/C clutch cycles or when the engine is accelerated rapidly. If the drive belt tensioner movement is constant without A/C clutch cycling or acceleration, a pulley or shaft is probably bent or a pulley is out of round. In rare cases, excessive drive belt rideout (uneven depth of grooves in drive belt) can cause excessive drive belt tensioner movement. This condition can he checked by installing the suspect drive belt with a known good original equipment drive belt and repeating the observation. Drive Belt Misalignment CAUTION: Incorrect drive belt installation will cause excessive drive belt wear and may cause the drive belt to come off the drive pulleys. Note: Original equipment drive belts are made of a special cord construction and are subjected to special testing before they are approved for use. Non-standard new drive belts may track differently or incorrectly. If a new drive belt tracks incorrectly, install a new original equipment drive belt to avoid performance failure or loss of drive belt. With the engine running, check drive belt tracking (the position of the drive belt on one of the grooveless pulleys, idlers or drive belt tensioner. If the edge of the drive belt rides beyond the edge of the pulley, noise and premature wear may result). If a drive belt tracking condition exists, visually check the drive belt tensioner for damage, especially the mounting pad surface. If the drive belt tensioner is not installed correctly with the locating pins in the locating holes, the mounting surface pad will be out of position. This will result in abnormal drive belt tension and chirp and squeal noises. If the above procedures do not correct the drive belt noise, install a new drive belt. However, the drive belt noise may return (with mileage) if one of the above conditions still exists uncorrected. With engine running, visually observe the grooves in the pulleys (not the pulley flanges) for excessive wobble. Install new components as required. - Check all accessories, mounting brackets and drive belt tensioner, for any interference that would prevent the component from mounting properly. Correct any interference condition and recheck belt tracking. - Tighten all accessories, mounting brackets and drive belt tensioner retaining hardware to specification. Recheck drive belt tracking. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 2384 Drive Belt: Service and Repair Removal and Installation 1. Remove the air cleaner outlet tube. 2. Remove the drive belt. 1 Rotate the drive belt tensioner counterclockwise. 2 Remove the drive belt. 3. Note: Refer to Component Locations for proper drive belt routing. See: Locations To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Component Information > Service and Repair Air Cleaner Housing: Service and Repair REMOVAL 1. Disconnect the air cleaner assembly. ^ Loosen the clamp and disconnect the outlet tube. ^ Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the air cleaner assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair NOTE: The air distribution system of this vehicle cannot be equipped with a cabin air filter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service and Repair Evaporative Canister Filter: Service and Repair REMOVAL 1. Open the liftgate, lower and remove the spare tire. 2. Disconnect the battery ground cable. For additional information refer to Battery. WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 3. Disconnect the two chassis emissions lines from the evaporative emission tube. WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 4. Remove the evaporative emissions canister bolts. 5. Remove the evaporative emission canister with bracket assembly. 1 Disconnect the canister vent solenoid electrical connector. 2 Remove the EVAP canister with bracket assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service and Repair > Page 2395 6. Disconnect the canister vent hose. 7. Remove the evaporative emission dust separator. INSTALLATION 1. To install, reverse the removal procedure. ^ Leak test the evaporative emission system. For additional information, refer to Evaporative Emission System Leak Test. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. For additional information, refer to Evaporative Emission Repair Verification Drive Cycle. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Service and Repair Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications Fluid Filter - A/T: Specifications Transmission fluid filter screws 71 - 97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications > Page 2399 Fluid Filter - A/T: Service and Repair Removal 1. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. Loosen the nut and position the heat shield out of the way. 2. Place a drain pan under the transmission fluid pan. 3. Drain transmission fluid. - Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front transmission fluid pan bolts. Pry the rear of the transmission fluid pan down and allow fluid to drain. After fluid is drained remove the front two transmission fluid pan bolts. 4. Remove the transmission fluid pan. 1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications > Page 2400 5. Remove and discard the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. 7. Flush the transmission fluid cooler and transmission fluid cooler lines. Installation 1. CAUTION: Lubricate fluid filter O-rings with MERCON(R) V; Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON(R) V or they may be damaged. Lube and install new O-rings onto the transmission fluid filter. Install a new transmission fluid filter. Position transmission fluid filter on the main control valve body. 2. CAUTION: Make sure wire harness is not pinched under filter. Install transmission fluid filter screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications > Page 2401 3. Position the oil pan magnet in the transmission fluid pan. 4. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align the transmission fluid pan. - Loosely install the transmission fluid pan screws. 5. Tighten the transmission fluid pan screws. - Use a crisscross sequence to tighten the transmission fluid pan screws. 6. Position the servo heat shield over the servos and clip it to the pan rail. 7. Lower the vehicle. 8. Note: When filling a dry transmission and converter start with a minimum of 3.7 liters (4 quarts). Fill transmission to the proper fluid level and check for proper transmission operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications > Page 2402 - Use MERCON V; Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON V. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR 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. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2407 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL SERVICE TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR 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. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and attach the Fuel Pressure Gauge. 2. Open the manual valve on the Fuel Pressure Gauge slowly and relieve the fuel pressure. NOTE: Open the manual valve slowly to relieve the system pressure. This may drain fuel from the system. Place the fuel in a suitable container. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2408 Fuel Pressure Gauge Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Oil bypass filter 10 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2421 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2422 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2428 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2429 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Page 2430 Heater Hose: Specifications Heater hose bracket bolts 27 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Page 2431 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications Hose/Line HVAC: Specifications Peanut Fitting Nut 7-9 Nm A/C Line To Condenser Nut 6.8-9.2 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > Page 2435 Hose/Line HVAC: Description and Operation NOTE: Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. The condenser to evaporator tube contains high pressure liquid refrigerant upstream of the A/C evaporator core orifice. The A/C manifold and tube is attached to the A/C compressor with O-ring seals and has the following features: - The upstream side contains low pressure refrigerant gas. - The downstream side contains high pressure refrigerant gas and a fitting used to mount a serviceable high-pressure A/C charge port valve. - The downstream side also contains a fitting used to mount the A/C pressure cut-off switch. A long-travel Schrader-type valve stem core is installed in the fitting so that the A/C pressure cut-off switch can be removed without discharging the A/C system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > Page 2436 Hose/Line HVAC: Service and Repair REMOVAL 1. Perform the Refrigerant Discharging and Recovery Procedure. 2. Disconnect the condenser to evaporator tube from the A/C condenser core. 3. Disconnect the condenser to evaporator tube spring lock coupling from the A/C evaporator core and remove the condenser to evaporator tube. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > Page 2437 Spring Lock Coupling Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Pressure Hose to Power Steering Pump 48 ft.lb Power Steering Pump Bolts 18 ft.lb Steering Gear Pressure Fittings 22 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications > Page 2441 Power Steering Line/Hose: Service and Repair Special Tools Special Service Tool(s) Removal 1. Refer to the Description and Operation for the hose routing and retention points. Installation 1. When connecting a fitting with a seal ring, a new seal ring must be installed. ^ The special tool is used to install the return line connector seal and the pressure line connector seal. 2. Fill and leak check the system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Brake Fluid High Performance DOT 3 Dot 4 may be used if Dot 3 is not available. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 2446 Brake Fluid: 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 eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Clean, fresh Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A is the only brake fluid that should be used in Ford vehicles. ^ Do not reuse brake fluid drained or bled from the system. ^ Do not use brake fluid that has been stored in an open container. ^ Do not use contaminated brake fluid. ^ Do not mix different types of brake fluid. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications Clutch Fluid Type DOT-3 Brake Fluid Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 2454 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity 16.3 qt (US) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 2457 Coolant: Fluid Type Specifications Antifreeze Type Ford Premium Engine Coolant (Green in color) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid .............................................................................................................................. ..................................................................... 10.0 qts Note: Approximately Dry Fill Capacity Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 2462 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ............................................................. MERCON V Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter Fluid - A/T: Service and Repair Fluid Pan, Gasket and Filter Fluid Pan, Gasket and Filter Removal 1. Raise and support the vehicle. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 2. Place a drain pan under the transmission fluid pan. 3. Drain transmission fluid. - Disconnect the LH three-way catalytic converter heated oxygen sensor connectors and remove the converter. - Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow fluid to drain. After fluid is drained, remove the front two transmission fluid pan screws. 4. Remove the transmission fluid pan. 1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 2465 5. Remove and discard the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. 7. Flush the transmission fluid cooler and transmission fluid cooler lines. Installation 1. CAUTION: Lubricate fluid filter O-rings with MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON (R) V or they may be damaged. Lube and install new O-rings onto the transmission fluid filter. Install a new transmission fluid filter. ^ Position transmission fluid filter on the main control valve body. 2. CAUTION: Make sure wire harness is not pinched under filter. Install transmission fluid filter screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 2466 3. Position the oil pan magnet in the transmission fluid pan. 4. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align the transmission fluid pan. ^ Loosely install the transmission fluid pan screws. 5. Tighten the transmission fluid pan screws. ^ Use a crisscross sequence to tighten the transmission fluid pan screws. 6. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 7. Lower the vehicle. 8. NOTE: When filling a dry transmission and converter, start with a minimum of 3.7 liters (4 quarts). Fill transmission to the correct fluid level and check for correct transmission operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 2467 ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON(R) V. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 2468 Fluid - A/T: Service and Repair Drain and Refill W/Automated Equipment Transmission Fluid Drain and Refill-Automated Equipment Special Tool(s) Draining CAUTION: Use only clean automatic transmission fluid. Do not use any supplemental transmission fluid additives, treatments or cleaning agents. The use of these materials can affect the operation of the transmission, resulting in internal component failure. CAUTION: Always refer to the instructions supplied with the flush and fill machine. NOTE: This is a new procedure for draining and adding transmission fluid using a suitable transmission flush and fill machine. 1. With the vehicle in PARK, position on a hoist. 2. Use a suitable flush and fill machine to change the fluid. 3. When connecting the flush and fill machine, connect the machine to the fluid cooler tube after the fluid cooler on the cooler return tube. This will help remove any foreign material trapped in the fluid coolers. 4. Carry out the fluid exchange process. Refill 1. Use only clean automatic transmission fluid. 2. Once the fluid exchange has been completed, disconnect the flush and fill machine. Reconnect any disconnected fluid cooler tubes. 3. Lower the vehicle. 4. With the engine running and the transmission at normal operating temperature 66-77°C (150-170°F), check and adjust the transmission fluid level and check for any leaks. If fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until the correct level is achieved (fluid should be in the cross-hatched area of the fluid level indicator). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 2469 Fluid - A/T: Service and Repair Vehicles Not Equipped With Torque Converter Drain Plug Transmission Fluid Drain and Refill- Vehicles Not Equipped With Torque Converter Drain Plug Draining CAUTION: Use only clean automatic transmission fluid. Do not use any supplemental transmission fluid additives, treatments or cleaning agents. The use of these materials can affect the operation of the transmission, resulting in internal component failure. 1. With the vehicle in PARK, position on a hoist. 2. NOTE: If equipped, the transmission servo heat shield must be unclipped from the fluid pan rail and positioned aside for fluid pan removal. If equipped, loosen the nut and position the heat shield aside. 3. Place a drain pan under the transmission fluid pan. 4. Drain the transmission fluid. ^ Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow the fluid to drain. After the fluid is drained, remove the front two transmission fluid pan screws. 5. Remove the transmission fluid pan. 1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 2470 6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. Refill 1. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align the transmission fluid pan ^ Loosely install the transmission fluid pan screws. 2. Tighten the transmission fluid pan screws. ^ Tighten the transmission fluid pan screws in a crisscross sequence. 3. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 4. Lower the vehicle. 5. NOTE: When filling a dry transmission and converter, start with a minimum of 3.7 liters (4 quarts). With the engine running and the transmission at normal operating temperature 66-77°C (150-170°F), check and adjust the transmission fluid level and check for any leaks. If fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until the correct level is achieved (fluid should be in the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 2471 cross-hatched area of the fluid level indicator). 6. Apply the park brake, and start the engine. 7. Move the range selector lever through all the gears. 8. Check the transmission fluid level. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information > Page 2476 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information > Page 2477 Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Manual Transmission Capacity ............................................................................................................................................... ................................................................... 2.7 Quarts Note: Approximate refill. Service refill capacity is determined by filling the transmission to the bottom of the filler hole with the vehicle on a level surface. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 2480 Fluid - M/T: Fluid Type Specifications Manual Transmission Fluid .................................................................................................................. ............................................................. Mercon ATF Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Refill ..................................................................................................................................................... ............................................................. 5.5-5.8 pints Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 2485 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A for 4.0L SOHC and 4.0L EI with a conventional differential. Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A for 4.0L SOHC and 4.0L EI with a limited slip differential and 5.0L. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications Technical Service Bulletin # 02-1-9 Date: 020121 Engine Oil - Oil Recommendations/Applications Article No. 02-1-9 01/21/02 ENGINE - ENGINE OIL - RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30 MOTOR OILS - GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY FORD: 1992-2002 CROWN VICTORIA 1993-1994 TEMPO 1993-1997 THUNDERBIRD 1993-2002 ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 1998-2002 ESCORT ZX2 2000-2002 FOCUS 1993-1996 BRONCO 1993-1997 AEROSTAR 1993-2002 E SERIES, F-150, RANGER 1995-2002 WINDSTAR 1997-1999 F-250 LD 1997-2001 EXPLORER 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1991-2002 TOWN CAR 1993-1998 MARK VIII 1993-2002 CONTINENTAL 2000-2002 LS 1998-2002 NAVIGATOR MERCURY: 1992-2002 GRAND MARQUIS 1993-1994 TOPAZ 1993-1997 COUGAR 1993-1999 TRACER 1993-2002 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1997-2001 MOUNTAINEER This article is being republished in its entirety to update the vehicle models, engines and years affected. NOTE PLEASE REFER TO THE VEHICLE APPLICATION LIST LATER IN THIS TSB FOR A COMPLETE LIST OF VEHICLES AFFECTED BY THIS TSB. ISSUE Ford Motor Company now recommends SAE 5W-20 viscosity grade for servicing most gasoline and flexible fueled vehicles. ACTION All 2001 and 2002 vehicles where SAE 5W-20 is specified should be serviced at the recommended oil change intervals using SAE 5W-20. This oil is an improved formulation to improve fuel economy. Testing has validated this viscosity grade can be used in many previous model year vehicles. It is recommended ALL vehicles on the following Vehicle Application Listing be service with SAE 5W-20. All 2001-2002 vehicles other than those listed in the "Exception 2001 Vehicles" or "Exception 2002 Vehicles" chart are being filled with SAE 5W-20 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2490 motor oil at the factory and should also be serviced with SAE 5W-20 oil. Exception 2001 Vehicles Exception 2002 Vehicles NOTE IF VEHICLE IS NOT LISTED IN THIS APPLICATION, SAE 5W-30 OIL IS RECOMMENDED. REFER TO TSB 99-8-16. Parts Block OTHER APPLICABLE ARTICLES: 99-8-16 SUPERSEDES: 01-4-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 497000, 499000 Veh. App. Listing Approved For SAE 5W-20 Motor Oil ^ 1993-1996 1.9L Escort/Tracer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2491 ^ 1995-2000 2.0L Zetec Contour/Mystique ^ 1999-2002 2.0L Cougar ^ 1997-2002 2.0L Escort/Tracer ^ 1998-2002 2.0L Escort ZX2 ^ 2000-2002 2.0L Focus ^ 2001-2002 2.0L Escape ^ 1993-1997 2.3L Ranger ^ 1993-1994 2.3L Mustang ^ 1993-1994 2.3L Tempo/Topaz ^ 1998-2001 2.5L Ranger ^ 1995-2000 2.5L Contour/Mystique ^ 1999-2002 2.5L Cougar ^ 2001-2002 3.0L 4V Escape ^ 1996-2001 3.0L 4V Taurus/Sable ^ 1993-2002 3.0L (Vulcan) Aerostar/Ranger, ^ Taurus/Sable (Flexible Fuel and Gas) ^ 1995-2000 3.0L (Vulcan) Windstar ^ 1993-1994 3.0L (Vulcan) Tempo/Topaz ^ 2000-2002 3.0L 4V Lincoln LS ^ 1995-2002 3.8L Windstar ^ 1993-1997 3.8L Taurus/Sable, ^ Thunderbird/Cougar, Continental ^ 1994-2002 3.8L Mustang ^ 2002-2002 3.9L 4V Lincoln LS ^ 1997-2002 4.2L (SPI) F-150 (under 8500 GVW only), E-Series ^ 1996-2002 4.6L 2V Mustang ^ 1992-2002 4.6L Crown Victoria/Grand Marquis ^ 1991-2002 4.6L Town Car ^ 1994-1997 4.6L 2V Thunderbird/Cougar ^ 1996-2002 4.6L 4V Mustang Cobra ^ 1995-2002 4.6L 4V Continental ^ 1993-1998 4.6L 4V Mark VIII Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2492 ^ 1997-2002 4.6L 2V Triton F-150/250 (under 8500 GVW only), E-Series, Expedition ^ 1993-1999 4.9L E-Series, F-Series ^ 1993-1995 5.0L Mustang/Mustang Cobra ^ 1993-1993 5.0L Thunderbird/Cougar ^ 1997-2001 5.0L Explorer/Mountaineer ^ 1993-1996 5.0L E-Series, F-Series, Bronco ^ 2000-2002 5.4L Excursion ^ 1998-2002 5.4L 2V/4V Navigator ^ 1997-2002 5.4L 2V F-1501250 (under 8500 GVW only), Expedition, E-Series, E-350 Chassis/RV/Cutaway ^ 1993-1997 5.8L F-Series, Bronco ^ 1993-1996 5.8L E-Series ^ 2000-2002 6.8L Excursion ^ 1997-2002 6.8L E-Series, E-350 Chassis/RV/Cutaway ^ 1999-2002 6.8L Super Duty F-Series 250 HD/350/450/550 Motorhome ^ 1993-1998 7.5L All Vehicles NOTE FOR 1993 THROUGH 1998 MODEL YEAR FFV USE XO-10W30-FFV. NOTE THE "EXCEPTION 2001-2002 VEHICLES" SHOULD BE SERVICED WITH SAE 5W-30 MOTOR OIL Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter ............................................................................................................................................ ............................................................. 4.7L (5.0 Qt) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2495 Engine Oil: Fluid Type Specifications Engine Oil Type ................................................................................................................................... ............................................... SAE 5W-30 Motor Oil Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Mercon V(R) Fluid Usage TSB 07-1-7 01/22/07 MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER STEERING SYSTEMS FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort 2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53 Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007 Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series 2000-2007 F-650, F-750 2006-2007 Low Cab Forward LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar 2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002 Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid for power steering systems originally requiring MERCON(R). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 2500 ACTION Beginning immediately all power steering 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 Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. CAUTION APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 2501 Power Steering Fluid: Specifications / / Power Steering Fluid Type MERCON(R) ATF Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications System Capacity 30 oz (US) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 2506 Refrigerant: Fluid Type Specifications Refrigerant Type Ford YN-19 (R-134a) Specification WSH-M17B19-A Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 2507 Refrigerant: Service Precautions The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun. Ozone Depletion Scientific research performed over the past 15 years links the release of chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone depletion. When CFCs are released into the atmosphere, they eventually reach the ozone layer located in the stratosphere where they react with and destroy ozone molecules. Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown to lead to higher incidents of cancer as well as global warming. When viewed from a global perspective, ozone depletion holds an enormous potential for damage. Upper Level Vs. Ground Level Ozone Confusion often arises when we hear about the necessity of the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial but the same compound, when located at ground level, is harmful to humans, animals, crops and vegetation. Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with nitrogen oxides (NOx) in the presence of sunlight and heat. Montreal Protocol In response to the growing body of evidence demonstrating the detrimental effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become signatories to this agreement leading to an end of production of R12 in December, 1995, in all developed countries. As established by the Montreal Protocol, R12 production in developed countries has ceased. Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to control both the production and use of (CFC)s for refrigerant applications including mobile vehicle air conditioning systems. Additional Information Sources For more complete and detailed explanations of the above policies, please refer to: http://www.epa.gov/ozone/ Technician Certification Organizations providing technician refrigerant recovery and recycling certification include: National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2 Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/ International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX 76147-2000 Phone: (817) 732-4600 Fax: (817) 732-9610 http://www.imaca.org/ Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041 Phone: 215-679-2220 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 2508 Fax: 215-541-4635 http://www.macsw.org/ Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 2509 Refrigerant: Service and Repair SPECIAL SERVICE TOOL(S) 1. Prior to recovering the refrigerant system, you must verify the purity of the refrigerant. For additional information, refer to Refrigerant Identification Testing. See: Heating and Air Conditioning/Testing and Inspection/Component Tests and General Diagnostics/Identifying Refrigerants 2. Connect the R-134a A/C refrigerant center to the low and high-pressure service gauge port valves. NOTE: Some R-134a service centers require the use of an A/C manifold gauge set. For additional information, refer to Manifold Gauge Set Connection. See: Heating and Air Conditioning/Service and Repair/Manifold Gauge Set Connection 3. Perform the Refrigerant Discharging and Recovery Procedure. 4. Once the refrigerant center has recovered the vehicle A/C system refrigerant, close the refrigerant center inlet valve (if so equipped). Then switch off the power supply. 5. Allow the vehicle A/C system to remain closed for about two minutes. Observe the system vacuum level as shown on the gauge. If the pressure does not rise, disconnect the recovery station hose(s). 6. If the system pressure rises, repeat steps 2 through 5 until the vacuum level remains stable for two minutes. 7. Carry out the required repairs, then Perform the Evacuation and Charging Procedure. For additional information, refer to Evacuation and Charging. See: Heating and Air Conditioning/Service and Repair/Evacuation and Charging Procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications System Capacity 9 oz (US) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 2514 Refrigerant Oil: Fluid Type Specifications Lubricant PAG Compressor Oil Type YN-12c Part Number F7AZ-19589-DA Specification WSH-M1C231-B Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 2515 Refrigerant Oil: Service and Repair CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant, and small amount is retained in each component. If certain components of the system are removed, some of the refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. 1. Rotate the A/C compressor shaft six to eight revolutions while collecting oil in a clean measuring device. - If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 ounces), pour the same amount plus 30 ml (1 ounce) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 ounces), pour the same amount drained of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 ounces), pour 85 ml (3 ounces) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. NOTE: Service A/C compressors are shipped without compressor oil. 2. For the suction accumulator/drier, drill two 1/2 inch holes in the suction accumulator/drier cylinder and drain the oil into a calibrated container. - Add a quantity of new oil to match that drained from the old suction accumulator/drier plus 60 ml (2 ounces) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. 3. For the A/C evaporator core, add 89 ml (3 ounces) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 2516 4. For the A/C condenser core , add 30 ml (1 ounce) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B to the A/C condenser core or the suction accumulator/drier inlet tube. 5. Add 60 ml (2 ounces) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube when carrying out each of the following repairs: installation of a new A/C evaporator core orifice. - installation of a new A/C compressor pressure relief valve. - installation of a new refrigerant line. - repair of an O-ring seal leak. - repair of a charge port leak. 6. Installation of new components that do not require discharge of refrigerant and resulting oil loss, such as the A/C cycling switch and the A/C pressure transducer, do not require additional oil. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications Caliper bleeder screw, rear 15 ft.lb Caliper bleeder screw, front 15 ft.lb Master cylinder bleeder screw 70-159 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding Brake Bleeding: Service and Repair Brake Caliper Bleeding 1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was disconnected. Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 4. Tighten the disc brake caliper bleeder screw. Refer to Specifications. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2522 Brake Bleeding: Service and Repair Brake System 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 eyes 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 brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 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. NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 4. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 5. Tighten the RH rear bleeder screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2523 6. Repeat Steps 2, 3, 4 and 5 for the LH rear bleeder screw. 7. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 8. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 9. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH front disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 10. Tighten the RH front disc brake caliper bleeder screw. 11. Repeat Steps 7, 8, 9 and 10 for the LH front disc brake caliper bleeder screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2524 Brake Bleeding: Service and Repair Brake System Pressure Bleeding 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. 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. Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose to the fitting on the adapter. 3. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Open the valve on the bleeder tank. 5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw and remove the rubber hose. 6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the RH front disc brake caliper bleeder screw ending with the LH front disc brake caliper bleeder screw. 7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2525 Brake Bleeding: Service and Repair Four Wheel ABS Hydraulic Control Unit (HCU) NOTE: This procedure only needs to be performed if the 4-wheel anti-lock brake (4WABS) hydraulic control unit (HCU) has been installed new. 1. Connect the scan tool DCL cable adapter into the vehicle data link connector (DLC) under the dash, and follow the scan tool instructions for bleeding. 2. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master cylinder reservoir with the specified brake fluid. 3. Connect a clear drain tube to the RH rear bleeder screw and the other end in a container partially filled with recommended brake fluid. 4. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 5. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 6. Tighten the bleeder screw. 7. Repeat Steps 3 - 6 for the LH rear bleeder screw, the RH front bleeder screw and the LH front bleeder screw, in that order. 8. Repeat the conventional bleed procedure as outlined in Steps 3 - 7. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2526 Brake Bleeding: Service and Repair Master Cylinder Priming - In-Vehicle or Bench Special Tools WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes 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 brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 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. NOTE: When any part of the hydraulic system has been disconnected for repair or installation, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: When the brake master cylinder has been installed new or the system has been emptied or partially emptied, it must be primed to prevent air from entering the system. 1. For in-vehicle priming, disconnect the brake lines from the brake master cylinder. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2527 2. For bench priming, mount the brake master cylinder in a vise. 3. Install short brake tubes with the ends bent into the brake master cylinder reservoir. ^ Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. 4. For a new brake master cylinder, remove the cruise switch. 5. Fill the cruise switch with the specified brake fluid. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2528 6. Install the cruise switch. 7. Slowly depress the primary piston or, for in-vehicle priming, have an assistant slowly pump the brake pedal until clear brake fluid flows from both brake tubes with no air bubbles. 8. If necessary, install the brake master cylinder into the vehicle. 9. Remove the short brake tubes and install the master cylinder outlet tubes. 10. Loosen a brake outlet tube at the 4WABS hydraulic control unit (HCU). 11. NOTE: Refill the brake master cylinder reservoir as necessary. Have an assistant depress and hold the brake pedal. 12. Tighten the outlet tube fitting at the HCU. 13. Repeat the above three steps until no air bubbles are seen in the expelled brake fluid. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 2529 14. Repeat the above four steps for the remaining master cylinder outlet tube. 15. Connect one end of a flexible tube to the master cylinder bleeder screw. Submerge the other end in a container partially filled with the specified brake fluid. 16. Have an assistant pump and then hold firm pressure on the brake pedal. 17. NOTE: Refill the brake master cylinder reservoir as necessary. Loosen the master cylinder bleeder screw until brake fluid flows out of the drain tube. 18. Tighten the master cylinder bleeder screw. 19. Repeat the above three steps until there are no air bubbles in the expelled brake fluid. 20. Bleed the brake system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Page 2530 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING:To reduce the risk of personal injury, do not use any memory saver devices. NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram See: Restraint Systems/Air Bag Systems. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2535 7. Remove the two steering wheel back cover plugs. 8. Remove the two driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. 10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical connector at the clockspring. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2536 11. Open the glove compartment door to access the passenger air bag module mounting screws. 12. Remove the two screws. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove box opening, push out on the passenger air bag module and separate it from the instrument panel. 14. Disconnect the electrical connector and remove the passenger air bag module. 15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the passenger air bag module electrical connector. Vehicles equipped with seat side air bags Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2537 16. Disconnect the passenger seat side air bag module electrical connector located under the passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector located under the driver seat. 19. Connect the restraint system diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical connector. All vehicles 20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground cable. Reactivation Procedure All vehicles 1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles equipped with seat side air bags 3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side air bag module electrical connector located under the driver seat. 4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint system diagnostic tool from the body harness side of the passenger seat side air bag module electrical connector located under the passenger seat. 6. Connect the passenger seat side air bag module electrical connector All vehicles 7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air bag module electrical connector. 8. Install the passenger air bag module. 9. Connect the passenger air bag module electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2538 10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical connector at the clockspring. 11. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag module to the steering wheel. 12. Install the two driver air bag module retaining bolts. 13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON. 15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 17. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2539 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle battery connected? Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2540 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Prove out the system means to turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2546 Fuse 1 - 18 Fuse 19 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2547 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2548 Fuse 1 - 10 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2549 Fuse 11 - 31 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2550 Fuse 32 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2551 Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2552 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2553 Relays Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2554 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2555 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2556 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2559 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2560 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2561 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2562 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2563 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2564 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2565 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2566 Fuse: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2567 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2568 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2569 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2570 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2571 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2572 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2575 Fuse 1 - 18 Fuse 19 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2576 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2577 Fuse 1 - 10 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2578 Fuse 11 - 31 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2579 Fuse 32 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2580 Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2581 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2582 Relays Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2583 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2584 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2585 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse Block: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2590 Fuse 1 - 18 Fuse 19 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2591 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2592 Fuse 1 - 10 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2593 Fuse 11 - 31 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2594 Fuse 32 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2595 Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2596 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2597 Relays Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2598 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2599 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2600 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2603 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2604 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2605 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2606 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2607 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2608 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2609 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2610 Fuse Block: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2611 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2612 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2613 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2614 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2615 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2616 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse Block: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2619 Fuse 1 - 18 Fuse 19 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2620 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2621 Fuse 1 - 10 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2622 Fuse 11 - 31 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2623 Fuse 32 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2624 Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2625 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2626 Relays Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2627 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2628 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2629 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2634 Fuse 1 - 18 Fuse 19 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2635 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2636 Fuse 1 - 10 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2637 Fuse 11 - 31 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2638 Fuse 32 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2639 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2640 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2641 Relays Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2642 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2643 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2644 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Module > Page 2647 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Module > Page 2648 Relay Box: Diagrams Auxiliary Relay Box #2 2 Door W/o Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Module > Page 2649 4 Door W/Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay Module > Page 2650 2 Door W/Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2653 Fuse 1 - 18 Fuse 19 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2654 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2655 Fuse 1 - 10 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2656 Fuse 11 - 31 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2657 Fuse 32 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2658 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2659 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2660 Relays Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2661 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2662 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2663 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Locations > Page 2668 Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) Malfunction Indicator Lamp (MIL) Check Engine, Service Engine Soon Or ISO Standard Engine Symbol The Malfunction Indicator Lamp (MIL) (Figure 15) alerts the driver that the Powertrain Control Module (PCM) has detected an OBD II emission-related component or system fault. When this occurs, an OBD II Diagnostic Trouble Code (DTC) will be set. ^ The MIL is located on the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or ISO standard engine symbol (Figure 16). ^ Power is supplied to the MIL whenever the ignition switch is in the RUN or START position. ^ The MIL will remain on in the RUN/START mode as a bulb check during the instrument cluster proveout for approximately 4 seconds. ^ If the MIL remains on after the bulb check: The PCM illuminates the MIL for an emission related concern and a DTC will be present. - The instrument cluster will illuminate the MIL if the PCM does not send a control message to the instrument cluster. - The PCM is operating in the Hardware Limited Operation Strategy (HLOS). - The MIL circuit is shorted to ground. ^ If the MIL remains off (during the bulb check): Bulb is damaged. - MIL circuit is open. ^ To turn off the MIL after a repair, a reset command from the Scan Tool must be sent, or three consecutive drive cycles must be completed without a fault. ^ For any MIL concern, GO to Computers and Control Systems/Testing and Inspection. ^ If the MIL blinks at a steady rate, a severe misfire condition could possibly exist. ^ If the MIL blinks erratically, an intermittent open B+ to the bulb or an intermittent short to ground in the MIL circuit exist. Also, the PCM can reset while cranking if battery voltage is low. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation Oil Change Reminder Lamp: Description and Operation If the connection to the oil temperature sensor is open circuit or shorted, the message center display will read OIL TEMP SIGNAL ERROR instead of displaying the PERCENTAGE OIL LIFE LEFT during system cheek sequence. One of these warning messages is displayed when the engine oil life remaining is five percent or less. - When oil life left is between five percent and zero percent, the "CHANGE OIL SOON" message will be displayed. - When oil life left reaches zero percent, the "OIL CHANGE REQUIRED" message will be displayed. The message center indicator will indicate the percent of oil life remaining during System Check. This percentage is based on the driving history and the time since the last oil change. In order to ensure accurate oil life left indications, the driver should only carry out the OIL CHANGE RESET procedure, as described in the Owner's Guide, after an oil change. To calculate the percentage of oil life remaining, the oil life feature uses: - oil temperature sensor input - tachometer input from the PCM - vehicle speed signal input - clock time (maintained internally by the message center) - The oil life will decrease from 100 percent to 0 percent in no more than 12,070 km (7,500 mile) or 6 months. It will reach zero percent sooner under different driving conditions. - The percentage of oil life remaining is the second display in the system check sequence. - When oil life remaining is between five percent and zero percent, the "CHANGE OIL SOON" message will be displayed. - When oil life left reaches zero percent, the "OIL CHANGE REQUIRED" message will be displayed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation > Page 2672 Oil Change Reminder Lamp: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation > Page 2673 Oil Change Reminder Lamp: Service and Repair Oil Change Reset Press the OIL CHANGE RESET control to reset the oil life feature to 100% (or your personalized oil reset percentage) (at optimal driving conditions, 100% oil life is equivalent to a maximum of 12,000 kilometers [7,500 miles]). After you have the oil changed, you must press and hold the OIL CHANGE RESET control for five seconds. The message center will count down for five seconds. After a successful reset, the message center will display OIL LIFE RESET TO 100%. (If you have established a personalized oil reset percentage, the display will show that percentage instead of 100%.) This reset procedure should be performed only after an oil change to ensure accurate oil life indications. Your personalized oil reset percentage allows you to establish a smaller oil change interval than the manufacturer's recommended interval. To establish your personalized oil reset percentage: 1. Press and hold the OIL CHANGE RESET control and press the RESET control while the display is still counting gown the five seconds to reset. The display will change to START OIL LIFE AT XXX%. 2. Press the OIL CHANGE RESET control until the displayed percentage is the personalized oil reset percentage you desire. Your choices are 100%, 90%, 80%, 70%, 60%, 50% 40% and 30%. 3. Press the RESET control to complete the procedure. Pressing any control other than RESET of OIL CHANGE RESET will abort this procedure and will not establish your new personalized oil reset percentage. When your personalized oil reset percentage has been established, it will be used beginning with the completion of your next OIL CHANGE RESET procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Description and Operation Oil Level Warning Indicator: Description and Operation This warning message is displayed when the engine oil level is low. When the engine oil level is normal, the input to the message center indicator will be an open circuit. When the engine oil level is low, the low oil level sensor will close, grounding the input to the message center indicator and the warning will be displayed during the next ignition cycle of OFF to RUN. This low oil level sensor is only monitored when the ignition switch is OFF. There is a delay of up to 12 minutes in this monitoring in order to allow the oil to drain back into the oil pan and reach the correct level. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation JACKING WARNING: ^ THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE REAR JACK STORAGE AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. ^ DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. ^ MAKE SURE THE JACK AND JACK STANDS ARE PROPERLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. ^ WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK. Jacking Points - Front The front jacking point is a tab that extends from the lower control arm. Jacking Points - Rear 1. The rear jacking points are located on the rear axle tube. CAUTION: ^ Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to contact the cover at any point where the cover joins the housing. LIFTING Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 2681 Lifting Points Locate front hoist adapters and rear hoist adapters (top of frame arc) as indicated. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE REAR JACK STORAGE AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION: ^ Damage to the suspension, exhaust or steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement Technical Service Bulletin # 01B77 Date: 011001 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2690 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2691 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2692 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2693 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2694 ^ 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2695 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2696 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2697 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2698 ^ 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2699 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > NHTSA00V313000 > Oct > 00 > Recall 00V313000: Certification Label Non-Compliance Tires: Recalls Recall 00V313000: Certification Label Non-Compliance Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification." These vehicles were shipped from the assembly plant without Safety Certification Labels. Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash. Dealers will replace the certification labels. All vehicles were at dealerships and certification labels were affixed to these units on October 9, 2000. This recall is 100% complete. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2708 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2709 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2710 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2711 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2712 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2713 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2714 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 2720 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 SOHC VIN K SFI (2001)) 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 2725 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 2726 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 2727 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 2728 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 SOHC VIN K SFI (2001)) 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 2729 ^ 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 SOHC VIN K SFI (2001)) 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 2730 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 SOHC VIN K SFI (2001)) 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 2731 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 SOHC VIN K SFI (2001)) 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 2732 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 SOHC VIN K SFI (2001)) 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 2733 ^ 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 SOHC VIN K SFI (2001)) 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 2734 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement Technical Service Bulletin # 00L12 Date: 010101 Information 00L12 SPECIAL FIELD ACTION All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement Original - January 2001 Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances Attachment III ^ Technical Information Customer Notification Letter Supplement # 1, February 5, 2001 - Updated Information All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement Supplement # 2, February 19, 2001 - Updated Information All 2001 Model Year Passenger Cars and light Trucks up to and Including F550 Super Duty Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement Special Field Action 00L12, Supplement # 1 dated 2/05/01 - Updated Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2739 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2740 Attachment I - Administrative Information OASIS Will not be active for this program. PLEASE NOTE Correct all units in dealer inventory prior to delivery to the customer. DEALER - OWNER CONTACT An owner list will not be provided for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACES II manual for claims preparation and submission information. Attachment II - Labor Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2741 LABOR ALLOWANCES Attachment III - Technical Information SPECIAL FIELD ACTION 00L12 WARRANTY GUIDE SUPPLEMENT VEHICLES COVERED BY THE NEW TIRE WARRANTY All 2001 model year passenger cars and light trucks up to and including F550 Super Duty vehicles sold in the U.S., U.S. Territories, Mexico, and Canada, built through December 31, 2000. NOTE: Information regarding tire warranty will be included in the Warranty Guide for vehicles produced after December 31, 2000. SERVICE PROCEDURE 1. Obtain a copy of the Warranty Guide Supplement. NOTE: Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make copies of the Warranty Guide Supplement (attached to this document). 2. Locate the vehicle Warranty Guide (located in the glove compartment). 3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle. PLEASE NOTE: This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a copy of the Warranty Guide Supplement with their notification letter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2742 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2743 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2744 Supplement # 1 - Information Supplement # 1, February 5, 2001 - Updated Information Cover Letter Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2745 Attachment III ^ Technical Information Customer Notification Letter Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2746 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2747 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2748 Supplement # 1 - Attachment I OASIS Will not be active for this program. PLEASE NOTE Correct all units in dealer inventory prior to delivery to the customer. DEALER - OWNER CONTACT An owner list will not be provided for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACES II manual for claims preparation and submission information. Supplement # 1 - Attachment II Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2749 LABOR ALLOWANCES Supplement # 1 - Attachment III WARRANTY GUIDE SUPPLEMENT NOTE: Information regarding tire warranty will be included in the Warranty Guide for vehicles produced after the end date listed above. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2750 SERVICE PROCEDURE 1. Obtain a copy of the Warranty Guide Supplement. NOTE: Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make copies of the Warranty Guide Supplement (included in this document). 2. Locate the vehicle Warranty Guide (located in the glove compartment). 3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle. PLEASE NOTE: This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a copy of the Warranty Guide Supplement with their notification letter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2751 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2752 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2753 Supplement # 2 - Information Supplement # 2, February 19, 2001 - Updated Information Cover Letter Dealer Letter Attachment I ^ Administrative Information Attachment II ^Labor Allowances Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2754 Attachment III ^ Technical Information Apology Letter Customer Notification Letter Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2755 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2756 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2757 Supplement # 2 - Attachment I OASIS Will not be active for this program. PLEASE NOTE Correct all units in dealer inventory prior to delivery to the customer. DEALER - OWNER CONTACT An owner list will not be provided for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACES II manual for claims preparation and submission information. Supplement # 2 - Attachment II Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2758 LABOR ALLOWANCES Supplement # 2 - Attachment III WARRANTY GUIDE SUPPLEMENT NOTE: Information regarding tire warranty will be included in the Warranty Guide for vehicles produced after the end date listed above. SERVICE PROCEDURE Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2759 1. Obtain a copy of the Warranty Guide Supplement. Note: Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make copies of the Warranty Guide Supplement (attached to this document). 2. Locate the vehicle Warranty Guide (located in the glove compartment). 3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle. PLEASE NOTE: This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a copy of the Warranty Guide Supplement with their notification letter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2760 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2761 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2762 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > NHTSA00V313000 > Oct > 00 > Recall 00V313000: Certification Label Non-Compliance Tires: All Technical Service Bulletins Recall 00V313000: Certification Label Non-Compliance Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification." These vehicles were shipped from the assembly plant without Safety Certification Labels. Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash. Dealers will replace the certification labels. All vehicles were at dealerships and certification labels were affixed to these units on October 9, 2000. This recall is 100% complete. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 SOHC VIN K SFI (2001)) 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 2771 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 2772 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 SOHC VIN K SFI (2001)) 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 2773 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 SOHC VIN K SFI (2001)) 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 2774 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 2775 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 2776 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 2777 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 2783 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement Technical Service Bulletin # 00L12 Date: 010101 Information 00L12 SPECIAL FIELD ACTION All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement Original - January 2001 Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances Attachment III ^ Technical Information Customer Notification Letter Supplement # 1, February 5, 2001 - Updated Information All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement Supplement # 2, February 19, 2001 - Updated Information All 2001 Model Year Passenger Cars and light Trucks up to and Including F550 Super Duty Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement Special Field Action 00L12, Supplement # 1 dated 2/05/01 - Updated Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2788 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2789 Attachment I - Administrative Information OASIS Will not be active for this program. PLEASE NOTE Correct all units in dealer inventory prior to delivery to the customer. DEALER - OWNER CONTACT An owner list will not be provided for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACES II manual for claims preparation and submission information. Attachment II - Labor Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2790 LABOR ALLOWANCES Attachment III - Technical Information SPECIAL FIELD ACTION 00L12 WARRANTY GUIDE SUPPLEMENT VEHICLES COVERED BY THE NEW TIRE WARRANTY All 2001 model year passenger cars and light trucks up to and including F550 Super Duty vehicles sold in the U.S., U.S. Territories, Mexico, and Canada, built through December 31, 2000. NOTE: Information regarding tire warranty will be included in the Warranty Guide for vehicles produced after December 31, 2000. SERVICE PROCEDURE 1. Obtain a copy of the Warranty Guide Supplement. NOTE: Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make copies of the Warranty Guide Supplement (attached to this document). 2. Locate the vehicle Warranty Guide (located in the glove compartment). 3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle. PLEASE NOTE: This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a copy of the Warranty Guide Supplement with their notification letter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2791 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2792 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2793 Supplement # 1 - Information Supplement # 1, February 5, 2001 - Updated Information Cover Letter Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2794 Attachment III ^ Technical Information Customer Notification Letter Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2795 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2796 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2797 Supplement # 1 - Attachment I OASIS Will not be active for this program. PLEASE NOTE Correct all units in dealer inventory prior to delivery to the customer. DEALER - OWNER CONTACT An owner list will not be provided for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACES II manual for claims preparation and submission information. Supplement # 1 - Attachment II Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2798 LABOR ALLOWANCES Supplement # 1 - Attachment III WARRANTY GUIDE SUPPLEMENT NOTE: Information regarding tire warranty will be included in the Warranty Guide for vehicles produced after the end date listed above. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2799 SERVICE PROCEDURE 1. Obtain a copy of the Warranty Guide Supplement. NOTE: Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make copies of the Warranty Guide Supplement (included in this document). 2. Locate the vehicle Warranty Guide (located in the glove compartment). 3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle. PLEASE NOTE: This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a copy of the Warranty Guide Supplement with their notification letter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2800 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2801 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2802 Supplement # 2 - Information Supplement # 2, February 19, 2001 - Updated Information Cover Letter Dealer Letter Attachment I ^ Administrative Information Attachment II ^Labor Allowances Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2803 Attachment III ^ Technical Information Apology Letter Customer Notification Letter Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2804 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2805 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2806 Supplement # 2 - Attachment I OASIS Will not be active for this program. PLEASE NOTE Correct all units in dealer inventory prior to delivery to the customer. DEALER - OWNER CONTACT An owner list will not be provided for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACES II manual for claims preparation and submission information. Supplement # 2 - Attachment II Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2807 LABOR ALLOWANCES Supplement # 2 - Attachment III WARRANTY GUIDE SUPPLEMENT NOTE: Information regarding tire warranty will be included in the Warranty Guide for vehicles produced after the end date listed above. SERVICE PROCEDURE Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2808 1. Obtain a copy of the Warranty Guide Supplement. Note: Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make copies of the Warranty Guide Supplement (attached to this document). 2. Locate the vehicle Warranty Guide (located in the glove compartment). 3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle. PLEASE NOTE: This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a copy of the Warranty Guide Supplement with their notification letter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2809 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2810 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2811 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 2812 Tires: Specifications Tire Tread Depth P225/70R15 A/S 0.37 in P235/75R15 A/T 0.42 in P255/70R16 A/T 0.42 in Maximum Radial Runount Aluminum 0.040 in Steel 0.040 in Maximum Lateral Runout Aluminum 0.040 in Steel 0.040 in Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 2813 Tires: Service and Repair Removal 1. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel bearings. Note: To avoid damage or scratching to the center cap, place facing up when removed. Loosen the lug nuts. 1 Remove the center cap. 2 With the weight of the vehicle on the wheels, loosen the lug nuts. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 3. Raise and support the vehicle. 4. Remove the wheel and tire assembly. 1 Remove the lug nuts. 2 Remove the wheel and tire assembly, using a side-to-side rocking motion. Installation 1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. Clean the wheel hub mounting, surface and wheel pilot. 2. Install the tire and wheel assembly. 1 Position the tire and wheel assembly. 2 Install the lug trots hand-tight, then lower the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 2814 3. CAUTION: Failure to tighten the lug nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Tighten the lug nuts in a star pattern using a torque wrench or torque sticks. 4. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the center cap. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Recalls: > NHTSA00V313000 > Oct > 00 > Recall 00V313000: Certification Label Non-Compliance Wheels: Recalls Recall 00V313000: Certification Label Non-Compliance Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification." These vehicles were shipped from the assembly plant without Safety Certification Labels. Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash. Dealers will replace the certification labels. All vehicles were at dealerships and certification labels were affixed to these units on October 9, 2000. This recall is 100% complete. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 2828 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > NHTSA00V313000 > Oct > 00 > Recall 00V313000: Certification Label Non-Compliance Wheels: All Technical Service Bulletins Recall 00V313000: Certification Label Non-Compliance Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification." These vehicles were shipped from the assembly plant without Safety Certification Labels. Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash. Dealers will replace the certification labels. All vehicles were at dealerships and certification labels were affixed to these units on October 9, 2000. This recall is 100% complete. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 2838 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 2839 Wheels: Specifications Maximum Radial Runount Aluminum 0.045 in Steel 0.045 in Maximum Lateral Runout Aluminum 0.045 in Steel 0.045 in Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 2840 Wheels: Description and Operation WARNING: Do not mix different types of tires, such as radial, bias, or bias-belted, on the same vehicle except in emergencies. Vehicle handling can be seriously affected and can result in loss of control. Factory-installed tires and wheels are designed to operate satisfactorily with loads up to and including full-rated load capacity when inflated to recommended inflation pressures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel and Tire Wheels: Service and Repair Wheel and Tire Removal 1. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel bearings. Note: To avoid damage or scratching to the center cap, place facing up when removed. Loosen the lug nuts. 1 Remove the center cap. 2 With the weight of the vehicle on the wheels, loosen the lug nuts. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 3. Raise and support the vehicle. 4. Remove the wheel and tire assembly. 1 Remove the lug nuts. 2 Remove the wheel and tire assembly, using a side-to-side rocking motion. Installation 1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. Clean the wheel hub mounting, surface and wheel pilot. 2. Install the tire and wheel assembly. 1 Position the tire and wheel assembly. 2 Install the lug trots hand-tight, then lower the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel and Tire > Page 2843 3. CAUTION: Failure to tighten the lug nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Tighten the lug nuts in a star pattern using a torque wrench or torque sticks. 4. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the center cap. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel and Tire > Page 2844 Wheels: Service and Repair Wheel Leaks 1. Pinhole leaks in cast aluminum wheels compromise wheel integrity. Install a new wheel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Lubricate the new rear wheel bearing. - For 4.0L SOHC and 4.0L EI with limited slip rear axles and 5.0L vehicles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - For 4.0L SOHC and 4.0L EI with conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check Wheel Bearing: Testing and Inspection Wheel Bearing Check 1. Raise and support the vehicle. ^ Make sure the system is warmed up to normal operating temperature, as thermal expansion can be the cause of a strain problem. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Spin the tire by hand to check the wheel bearings for roughness. NOTE: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. 3. Grip each front tire at the top and bottom arid move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check > Page 2850 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the service procedures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check > Page 2851 Wheel Bearing: Testing and Inspection Wheel Bearing Inspection 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the tire is off the floor. 2. Note: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel assembly. Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, perform one of the following actions. ^ On 4x2 vehicles, adjust the front wheel bearings. ^ On 4x4 vehicles, install a new wheel hub. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Solid Rear Axle Wheel Bearing: Service and Repair Solid Rear Axle Special Tools Special Tools Removal 1. Remove the axle shaft. 2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the rear wheel bearing and the inner wheel bearing oil seal at the same time. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Solid Rear Axle > Page 2854 Note: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and wheel bearing oil seal together. Installation 1. Lubricate the new rear wheel bearing. - For 4.0L SOHC and 4.0L EI with limited slip rear axles and 5.0L vehicles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - For 4.0L SOHC and 4.0L EI with conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Solid Rear Axle > Page 2855 Wheel Bearing: Service and Repair Independent Rear Suspension Wheel Bearing Removal And Installation 1. Remove the wheel knuckle. 2. CAUTION: Make sure that the press adapter outside diameter is slightly smaller than the hub outside diameter or damage to the knuckle will result. Using a suitable press, remove the hub from the bearing. - Discard the hub. 3. NOTE: The retainer ring is tapered and must be installed flat side down. Remove the retainer ring. - Discard the retainer ring. 4. Using a suitable press, remove the bearing from the wheel knuckle. - Discard the bearing. 5. CAUTION: The hub and bearing cannot be reused after disassembly. To install. reverse the removal Procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications - Tighten the spindle nut while rotating the brake disc and hub. - Loosen the spindle nut. - Tighten the spindle nut while rotating the brake disc and hub. - Install the following components: 1 Install the nut retainer. 2 Install the cotter pin. 3 Install the hub grease cap. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel Nuts 135 Nm (100 lb/ft) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front Removal 1. Raise the vehicle on a hoist. 2. Remove the wheel and tire assembly. 3. Remove the brake disc and hub. 4. Using a suitable press, remove the wheel stud from the brake disc and hub. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 2865 Wheel Fastener: Service and Repair Rear Special Tool(s) Special Service Tool(s) Removal CAUTION: Never use a hammer to remove the wheel stud. Damage to the axle flange, hub flange, wheel bearing or hub bearing can result. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air shocks, which can result in shifting of the vehicle curing these operations. Turn the air suspension service switch off, if so equipped. 2. Raise the vehicle and install safety stands. 3. Remove the wheel and tire assembly. 4. Remove the rear disc brake caliper, rear disc support bracket and brake disc if so equipped. Support the rear disc brake caliper with safety wire. 5. Using the C-Frame and Clamp Assembly Tool, press the wheel stud from its seat and discard. Installation CAUTION: Never use air tools to install wheel studs. The serrations can be stripped from the stud. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 2866 1. Insert a new wheel stud in the hole in the axle flange, making sure the serrations are aligned with those made by the original wheel stud. 2. Seat new wheel studs in axle flange. - Place four flat washers over the outside end of the wheel stud. - Thread a standard wheel nut with the flat side against the washers. - Tighten the wheel nut until the wheel stud head seats against the back side of the flange. 3. Remove the wheel nut and flat washers. 4. Install the brake disc, rear disc support bracket the rear disc brake caliper, if so equipped. 5. Install the wheel and tire assembly. 6. Lower the vehicle. 7. Turn the air suspension service switch on, if so equipped. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation JACKING WARNING: ^ THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE REAR JACK STORAGE AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. ^ DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. ^ MAKE SURE THE JACK AND JACK STANDS ARE PROPERLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. ^ WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK. Jacking Points - Front The front jacking point is a tab that extends from the lower control arm. Jacking Points - Rear 1. The rear jacking points are located on the rear axle tube. CAUTION: ^ Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to contact the cover at any point where the cover joins the housing. LIFTING Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page 2870 Lifting Points Locate front hoist adapters and rear hoist adapters (top of frame arc) as indicated. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE REAR JACK STORAGE AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION: ^ Damage to the suspension, exhaust or steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System Variable Valve Timing Actuator: Description and Operation Variable Cam Timing System Variable Cam Timing System Overview The Variable Cam Timing System allows the exhaust cam to advance and retard at varying engine speeds. The purpose of this is to reduce exhaust emissions and increase fuel economy. As the exhaust cam retards in relation to the crankshaft position, residual exhaust gases are left in the combustion chamber. The residual gases cool the combustion chamber and are inert when mixed with the incoming fresh charge of fuel and air. This results in better fuel economy and lower Nitrogen Oxides (NOx) and Hydrocarbons (HG) the engine produces. The Exhaust Gas Recalculation System (EGR) is unnecessary on the 2.0L (4V) engine due to this feature. Variable Cam Timing The Variable Cam Timing (VCT) system consists of the control solenoid, five-tooth pulse ring (4+1) on exhaust camshaft, Intake Air Temperature (IAT) sensor, Engine Coolant Temperature (ECT) sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor, Crankshaft Position (CKP) sensor, Powertrain Control Module (PCM) (Figure 129). 1. The Powertrain Control Module (PCM) receives input signals from the Intake Air Temperature (IAT) sensor, Engine Coolant Temperature (ECT) sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor and Crankshaft Position (CKP) sensor for determining the operating conditions of the engine. 2. The Variable Cam Timing (VCT) system is enabled by the PCM when the proper conditions are met. The PCM disables the VCT system if a fault is detected. 3. The PCM calculates relative cam position using the CMP sensor and data from the (4+1) pulse ring mounted on the exhaust camshaft. Relative cam position is calculated by measuring the time between the rising edge of Profile Ignition Pickup (PIP) and the falling edge of Variable Cam Timing (VCT) pulse. 4. The PCM continually calculates a cam position error value based on the difference between the desired and actual position and a duty cycle is commanded for the VCT solenoid valve. Engine oil is allowed to flow to the VCT unit. 5. Oil flows to either side of the piston chamber changing a linear motion from the piston to a rotation motion from the helical mechanism in the VCT unit. During closed loop the PCM outputs a revised duty cycle to the VCT solenoid valve to correct for cam position error. Variable Cam Timing System HARDWARE Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 2878 Variable Cam Timing (VCT) Solenoid Valve Variable Cam Timing (VCT) Solenoid Valve The VCT solenoid valve (Figure 130) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam timing. Variable Cam Timing Unit Assembly Variable Cam Timing (VCT) Unit Assembly The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the piston to move linearly along the axis of the camshaft. This linear motion is translated into rotational camshaft motion through the helical spline coupling. A spring installed Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 2879 in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up to 30 degrees. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 2880 Variable Valve Timing Actuator: Description and Operation Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing Unit Assembly The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the piston to move linearly along the axis of the camshaft. This linear motion is translated into rotational camshaft motion through the helical spline coupling. A spring installed in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up to 30 degrees. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Description and Operation Variable Valve Timing Solenoid: Description and Operation VARIABLE CAM TIMING (VCT) SOLENOID VALVE Variable Cam Timing (VCT) Solenoid Valve The Variable Cam Timing (VCT) solenoid valve (Figure 130) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam timing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. For additional information, refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 2887 Compression Check: Testing and Inspection 1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery is correctly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No.1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of Super Premium SAE 5W-30 Motor Oil, XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test-Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 2888 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75 percent of the highest reading. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications Camshaft Bearing: Specifications Camshaft Bearing Cap Bolts Stage 1 6 Nm Stage 2 16 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications > Page 2893 Camshaft Bearing: Service and Repair NOTE: Ford does not provide timing marks or additional information for servicing of the timing chains/sprockets without the special tools listed in this procedure. Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications > Camshaft Gear/Sprocket Camshaft Gear/Sprocket: Specifications Camshaft sprocket bolt 63 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications > Camshaft Gear/Sprocket > Page 2898 Camshaft Gear/Sprocket: Specifications Camshaft Sprocket Bolt 63 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Intake Lobe Lift 0.259 in End Play 0.0003 - 0.007 in Exhaust Lobe Lift 0.259 in Maximum Allowable Lobe Lift Loss 0.005 in Journal to Bearing Clearance 0.002 - 0.004 in Journal to Bearing Clearance Service Limit 0.006 in Journal Diameter 1.100 - 1.104 in Bearing Inside Diameter 1.102 - 1.104 in Maximum Camshaft Journal Runout 0.002 in Hydraulic camshaft tensioner, RH 49 ft.lb Hydraulic camshaft tensioner, LH 49 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > LH Camshaft: Service and Repair LH NOTE: Ford does not provide timing marks or additional information for servicing of the timing chains/sprockets without the special tools listed in this procedure. Removal 1. Remove the camshaft roller followers. 2. Remove the LH hydraulic camshaft tensioner. 3. Remove the bolt and the camshaft sprocket. 4. Note: Mark the position of the camshaft bearing caps so they can be installed in the original position. Remove the bolts in the sequence shown and remove the camshaft bearing caps and the oil supply tube. 5. Remove the camshaft. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > LH > Page 2904 1. Note: Lubricate the parts with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G before installing. Install the camshaft. 2. Note: The camshaft bearing caps must be installed in the original position. Note: After installing the bolts, check the camshaft for free rotation. Position the oil supply tube, the camshaft bearing caps, and the bolts. - Tighten in the sequence shown in two stages. - Stage 1: Tighten to 6 Nm (53 inch lbs.). - Stage 2: Tighten to 16 Nm (12 ft. lbs.). 3. The camshaft must be re-timed. 4. Install the camshaft roller followers. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > LH > Page 2905 Camshaft: Service and Repair RH NOTE: Ford does not provide timing marks or additional information for servicing of the timing chains/sprockets without the special tools listed in this procedure. Special Tools Removal 1. Remove the camshaft roller followers. 2. Remove the RH hydraulic camshaft tensioner. 3. CAUTION: The right-hand camshaft sprocket bolt is a left-hand threaded bolt. Using the special tool, remove the bolt and the camshaft sprocket. 4. Note: Mark the position of the camshaft bearing caps so they can be installed in the original position. Remove the bolts in the sequence shown and remove the camshaft bearing caps and the oil supply tube. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > LH > Page 2906 5. Remove the camshaft. Installation 1. Note: Lubricate the parts with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford Specification WSS-M2C153-G before installing. Install the camshaft. 2. Note: The camshaft bearing caps must be installed in their original position. Note: After installing the bolts, check the camshaft for free rotation. Position the oil supply tube, the camshaft bearing caps, and the bolts. Tighten in the sequence shown in two stages: - Stage 1: Tighten to 6 Nm (53 inch lbs.). - Stage 2: Tighten to 16 Nm (12 ft. lbs.). 3. The camshaft must be re-timed. 4. Install the camshaft roller followers. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair Lifter / Lash Adjuster: Service and Repair Removal and Installation l. Remove the camshaft roller followers. 2. Remove the hydraulic lash adjusters. 3. Note: Lubricate the parts with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specifications WSS-M2C153-G prior to installing. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair Rocker Arm Assembly: Service and Repair Special Tools Removal 1. Remove the valve covers. 2. Remove the fuel supply manifold. 3. Note: Mark each camshaft roller follower to ensure its original position during reassembly. Using the special tool, remove the camshaft roller followers. 4. Note: Lubricate the parts with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G prior to installing. To install, reverse the removal procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System Variable Valve Timing Actuator: Description and Operation Variable Cam Timing System Variable Cam Timing System Overview The Variable Cam Timing System allows the exhaust cam to advance and retard at varying engine speeds. The purpose of this is to reduce exhaust emissions and increase fuel economy. As the exhaust cam retards in relation to the crankshaft position, residual exhaust gases are left in the combustion chamber. The residual gases cool the combustion chamber and are inert when mixed with the incoming fresh charge of fuel and air. This results in better fuel economy and lower Nitrogen Oxides (NOx) and Hydrocarbons (HG) the engine produces. The Exhaust Gas Recalculation System (EGR) is unnecessary on the 2.0L (4V) engine due to this feature. Variable Cam Timing The Variable Cam Timing (VCT) system consists of the control solenoid, five-tooth pulse ring (4+1) on exhaust camshaft, Intake Air Temperature (IAT) sensor, Engine Coolant Temperature (ECT) sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor, Crankshaft Position (CKP) sensor, Powertrain Control Module (PCM) (Figure 129). 1. The Powertrain Control Module (PCM) receives input signals from the Intake Air Temperature (IAT) sensor, Engine Coolant Temperature (ECT) sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor and Crankshaft Position (CKP) sensor for determining the operating conditions of the engine. 2. The Variable Cam Timing (VCT) system is enabled by the PCM when the proper conditions are met. The PCM disables the VCT system if a fault is detected. 3. The PCM calculates relative cam position using the CMP sensor and data from the (4+1) pulse ring mounted on the exhaust camshaft. Relative cam position is calculated by measuring the time between the rising edge of Profile Ignition Pickup (PIP) and the falling edge of Variable Cam Timing (VCT) pulse. 4. The PCM continually calculates a cam position error value based on the difference between the desired and actual position and a duty cycle is commanded for the VCT solenoid valve. Engine oil is allowed to flow to the VCT unit. 5. Oil flows to either side of the piston chamber changing a linear motion from the piston to a rotation motion from the helical mechanism in the VCT unit. During closed loop the PCM outputs a revised duty cycle to the VCT solenoid valve to correct for cam position error. Variable Cam Timing System HARDWARE Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 2917 Variable Cam Timing (VCT) Solenoid Valve Variable Cam Timing (VCT) Solenoid Valve The VCT solenoid valve (Figure 130) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam timing. Variable Cam Timing Unit Assembly Variable Cam Timing (VCT) Unit Assembly The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the piston to move linearly along the axis of the camshaft. This linear motion is translated into rotational camshaft motion through the helical spline coupling. A spring installed Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 2918 in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up to 30 degrees. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 2919 Variable Valve Timing Actuator: Description and Operation Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing Unit Assembly The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the piston to move linearly along the axis of the camshaft. This linear motion is translated into rotational camshaft motion through the helical spline coupling. A spring installed in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up to 30 degrees. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Specifications Balance Shaft: Specifications Balance shaft bolts 19 - 21 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft Chain Guide > Component Information > Specifications Balance Shaft Chain Guide: Specifications Balance shaft chain guide 80 - 97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft Chain Tensioner > Component Information > Specifications Balance Shaft Chain Tensioner: Specifications Balance shaft tensioner bolts 21 - 22 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Connectin Rod Bearing Clearance to Crankshaft - Desired 0.008-0.061 mm (0.0003-0.0024 in) Clearance to Crankshaft - Allowable 0.013-0.048 mm (0.0005-0.002 in) Bearing Wall Thickness 1.4-1.408 mm (0.0551-0.0554 in) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 2933 Connecting Rod Bearing: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Bolt Connecting Rod: Specifications Connecting Rod Bolt Install the connecting rod cap in the original position. Note: Do not exceed 20 Nm (15 ft. lbs.) when tightening the connecting rod nuts. Install and tighten the connecting rod nuts until they touch the connecting surface of the connecting rod cap. Tighten the connecting rod nuts simultaneously in two stages: - Stage 1: Tighten 20 Nm (15 ft. lbs.). - Stage 2: Tighten 90 degrees. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Bolt > Page 2938 Connecting Rod: Specifications Connecting Rod Bearings Clearance to Crankshaft Desired 0.0003 - 0.0024 in Clearance to Crankshaft Allowable 0.0005 - 0.002 in Bearing Wall Thickness 0.0551 - 0.0554 in Main Bearings Clearance to Crankshaft 0.0008 - 0.0015 in Clearance to Crankshaft Allowable 0.0005 - 0.002 in Bearing Wall Thickness 0.0709 - 0.0711 in Rod Length Center to Center 5.746 - 5.749 in Alignment (Bore-to-Bore Max. Diff.) Twist 0.0015 per 1.000 in Alignment (Bore-to-Bore Max. Diff.) Bend 0.0049 per 1.000 in Side Clearance (Assembled to Crankshaft) 0.0036-0.0106 in Piston Pin Bore or Bushing I.D. 0.943-0.944 in Rod Bearing Bore I.D. 2.237 in Rod Bearing Bore Out-of-Round 0.0004 in Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 2939 Connecting Rod: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Coolant Drain Plug, Cylinder Block > Component Information > Specifications Coolant Drain Plug: Specifications Engine block coolant drain plug 12 - 18 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Main Bearing - Clearance to Crankshaft 0.0008-0.0015 in Main Bearing - Clearance to Crankshaft (Allowable) 0.0005-0.002 in Bearing Wall Thickness 0.0709-0.0711 in Main Bearing Cap Bolts 72 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 2946 Crankshaft Main Bearing: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Main Bearing Journal Diameter 2.243 - 2.244 in Main Bearing Journal Runout Limit 0.002 in Main Bearing Journal Taper Maximum Per Inch 0.0003 in Connecting Rod Journal Maximum Out-of-Round 0.0003 in Crankshaft Free End Play 0.002 - 0.0126 in Main Bearing Journal Out-of-Round 0.0003 in Main Bearing Journal Runout TIR Maximum 0.002 in Main Bearing Journal Runout Service Limit 0.005 in Main Bearing Thrust Face Runout TIR Maximum 0.010 in Thrust Bearing Journal Length 1.039 - 1.041 in. Main and Rod Bearing Journal Finish RMS Maximum 72 and 88 Main Bearing Thrust Face Finish RMS Maximum 20 Connecting Rod Journal Diameter 2.125 - 2.126 in Connecting Rod Journal Taper Per Inch Maximum 0.0003 in Main bearing cap bolts 72 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 2950 Crankshaft: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications Engine Block Heater: Specifications Block heater screw 14 - 16 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Specifications > Page 2954 Engine Block Heater: Service and Repair Removal 1. Drain the cooling system. 2. Raise and support the vehicle. 3. Disconnect the connector. 4. Remove the block heater. 1 Note: Do not loosen the screw more than necessary for removal. Loosen the screw. 2 Twist and slide the block heater to release the retainer clip and discard the retainer clip. 3 Remove the block heater. Installation 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Pulley Bolt Stage 1 44 ft.lb Stage 2 Additional 90 degrees Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2958 Harmonic Balancer - Crankshaft Pulley: Service and Repair Special Tools Removal 1. Remove the fan shroud. 2. Remove the accessory drive belt. 3. CAUTION: This bolt is torque to yield and cannot he reused. Remove the damper bolt. 4. Using the special tool, remove the crankshaft pulley. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2959 1. Using the special tool, install the crankshaft pulley. 2. Install a new crankshaft pulley bolt. - Tighten in two stages: - Stage 1: Tighten to 60 Nm (44 ft. lbs.). - Stage 2: Tighten 90 degrees. 3. Install the accessory drive belt. 4. Install the fan shroud. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Bore Clearance Selective Fit 0.0012 - 0.002 in Diameter-Coded STD 3.952 - 3.528 in Diameter-Coded 0.5 3.972 in Diameter-Coded 1.0 3.990 - 3.991 in Pin Bore Diameter (Red) 0.945 in Pin Bore Diameter (Blue) 0.945 in Top Ring Groove Width 0.0645 -0 0654 in Bottom Ring Groove Width 0.075 - 0.0713 in Oil Ring Groove Width 0.1378 - 0.1399 in Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 2963 Piston: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Length 2.835 - 2.866 in Diameter (Red) 0.9446 - 0.9447 in Diameter (Blue) 0.9447 - 0.9449 in To Piston Pin Bore Clearance 0.0004 - 0.0006 in To Connecting Rod Bushing Clearance -0.0007 to -0.0017 in Press Fit Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications > Page 2967 Piston Pin: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Top Compression Ring Width 0.062 - 0.063 in Bottom Compression Ring Width 0.068 - 0.069 in Top Compression Side Clearance 0.002 - 0.003 in Bottom Compression Side Clearance 0.002 - 0.003 in Top Compression Ring 0.008 - 0.018 in Bottom Compression Ring Gap 0.018 - 0.028 in Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 2971 Piston Ring: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The 4.0L Push Rod engine has hydraulic lifters and requires no valve clearance adjustments. The 4.0L SOHC engine: - Manufacturer does not indicate whether the type of valve arrangement for this engine. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR 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. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 2979 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL SERVICE TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR 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. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and attach the Fuel Pressure Gauge. 2. Open the manual valve on the Fuel Pressure Gauge slowly and relieve the fuel pressure. NOTE: Open the manual valve slowly to relieve the system pressure. This may drain fuel from the system. Place the fuel in a suitable container. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 2980 Fuel Pressure Gauge Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair Rocker Arm Assembly: Service and Repair Special Tools Removal 1. Remove the valve covers. 2. Remove the fuel supply manifold. 3. Note: Mark each camshaft roller follower to ensure its original position during reassembly. Using the special tool, remove the camshaft roller followers. 4. Note: Lubricate the parts with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G prior to installing. To install, reverse the removal procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications Valve Cover: Specifications Valve cover bolts 80 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH Valve Cover: Service and Repair LH Removal CAUTION: This vehicle is equipped with a composite material fuel supply manifold. If the supply manifold is used as a leverage device, damage may occur to the supply manifold. Care must be taken when working around the fuel supply manifold. 1. Remove the upper intake manifold. 2. Disconnect the fuel line. 3. Disconnect the camshaft position (CMP) sensor electrical connector. 4. Disconnect the differential pressure feedback EGR transducer. 1 Disconnect the electrical connector. 2 Disconnect the vacuum hoses. 5. Disconnect the engine electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2989 6. Disconnect the electrical connector from the valve cover. 7. Disconnect the radio ignition interference capacitor electrical connector. 8. Disconnect the ignition coil electrical connector. 9. Disconnect the spark plug wires from the ignition coil. 10. Remove the valve cover. - Discard the gasket. 11. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2990 Valve Cover: Service and Repair RH Removal and Installation CAUTION: This vehicle is equipped with a composite material fuel supply manifold. If the supply manifold is used as a leverage device, damage may occur to the supply manifold. Care must be taken when working around the fuel supply manifold. 1. Remove the upper intake manifold. 2. Drain the engine cooling system. 3. Disconnect the upper radiator hose and tube. 1 Remove the bolt. 2 Release the hose clamp and position hose and tube aside. 4. Remove the heater hose bracket and disconnect the transmission dipstick tube. 5. Disconnect the spark plug wires. 6. Remove the valve cover. - Discard the gasket. 7. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Width Intake 0.06 - 0.094 in Exhaust 0.05 - 0.083 in Angle Degrees 45 deg Runout TIR Maximum 0.002 in Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Technical Service Bulletins > Customer Interest for Valve Spring: > 02-3-2 > Feb > 02 > Engine Control - MIL ON, DTC P0300 or P0301 Set Valve Spring: Customer Interest Engine Control - MIL ON, DTC P0300 or P0301 Set Article No. 02-3-2 02/18/02 ^ DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC) P0300/P0301 STORED IN MEMORY - VEHICLES EQUIPPED WITH 4.0L SOHC ENGINE ONLY ^ ELECTRICAL - LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED DIAGNOSTIC TROUBLE CODES (DTC) P0300/P0301 STORED IN MEMORY - VEHICLES EQUIPPED WITH 4.0L SOHC ENGINE ONLY ^ ENGINE - 4.0L SOHC - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED DIAGNOSTIC TROUBLE CODES (DTC) P0300/P0301 STORED IN MEMORY - VEHICLES EQUIPPED WITH 4.0L SOHC ENGINE ONLY FORD: 1997-2002 EXPLORER SPORT, EXPLORER 2001-2002 EXPLORER SPORT TRAC, RANGER MERCURY: 1997-2002 MOUNTAINEER ISSUE Some vehicles equipped with the 4.0L SOHC engine may exhibit a CHECK ENGINE LIGHT "ON" with Diagnostic Trouble Codes (DTC) P0300 (Random Misfire) or P0301. The DTC will set when the engine is operated at high RPM'S (4800 RPM and higher). The Misfire code results due to system interaction of higher than expected transient exhaust system backpressure (under heavy acceleration) coupled with valve spring resonance points experienced at these engine speeds. This interaction may cause the' exhaust valve to hang open at engine speeds of 4800 RPM and higher. ACTION Verify that the DTC sets only at 4800 RPM or higher. Remove current intake and exhaust valve springs and replace with new service intake and exhaust valve springs. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THIS REPAIR ONLY APPLIES TO P0300/P0301 DTC'S SET ABOVE 4800 RPM. THIS REPAIR WILL NOT CORRECT MISFIRE DTC'S SET AT LOWER RPM'S. NOTE PRIOR TO REPAIR, REFERENCE YOUR APPLICABLE WORKSHOP MANUAL FOR CORRECT VALVE SPRING REMOVAL/REPLACEMENT PROCEDURES. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Technical Service Bulletins > Customer Interest for Valve Spring: > 02-3-2 > Feb > 02 > Engine Control - MIL ON, DTC P0300 or P0301 Set > Page 3002 1. Gain access to the valve springs. 2. Remove (quantity 12) existing intake and exhaust valve springs F77Z-6513-M and replace with new service intake and exhaust valve springs 2L2Z-6513-AA. NOTE ALL "12" VALVE SPRINGS ("6" INTAKE AND "6" EXHAUST) MUST BE REPLACED IN ORDER TO MAINTAIN/ENSURE PROPER VALVETRAIN DYNAMICS. 3. Road test vehicle to verify repair. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 6513 42 OASIS CODES: 499000, 608000, 609000, 6100000, 611000, 611500, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Spring: > 02-3-2 > Feb > 02 > Engine Control - MIL ON, DTC P0300 or P0301 Set Valve Spring: All Technical Service Bulletins Engine Control - MIL ON, DTC P0300 or P0301 Set Article No. 02-3-2 02/18/02 ^ DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC) P0300/P0301 STORED IN MEMORY - VEHICLES EQUIPPED WITH 4.0L SOHC ENGINE ONLY ^ ELECTRICAL - LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED DIAGNOSTIC TROUBLE CODES (DTC) P0300/P0301 STORED IN MEMORY - VEHICLES EQUIPPED WITH 4.0L SOHC ENGINE ONLY ^ ENGINE - 4.0L SOHC - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED DIAGNOSTIC TROUBLE CODES (DTC) P0300/P0301 STORED IN MEMORY - VEHICLES EQUIPPED WITH 4.0L SOHC ENGINE ONLY FORD: 1997-2002 EXPLORER SPORT, EXPLORER 2001-2002 EXPLORER SPORT TRAC, RANGER MERCURY: 1997-2002 MOUNTAINEER ISSUE Some vehicles equipped with the 4.0L SOHC engine may exhibit a CHECK ENGINE LIGHT "ON" with Diagnostic Trouble Codes (DTC) P0300 (Random Misfire) or P0301. The DTC will set when the engine is operated at high RPM'S (4800 RPM and higher). The Misfire code results due to system interaction of higher than expected transient exhaust system backpressure (under heavy acceleration) coupled with valve spring resonance points experienced at these engine speeds. This interaction may cause the' exhaust valve to hang open at engine speeds of 4800 RPM and higher. ACTION Verify that the DTC sets only at 4800 RPM or higher. Remove current intake and exhaust valve springs and replace with new service intake and exhaust valve springs. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THIS REPAIR ONLY APPLIES TO P0300/P0301 DTC'S SET ABOVE 4800 RPM. THIS REPAIR WILL NOT CORRECT MISFIRE DTC'S SET AT LOWER RPM'S. NOTE PRIOR TO REPAIR, REFERENCE YOUR APPLICABLE WORKSHOP MANUAL FOR CORRECT VALVE SPRING REMOVAL/REPLACEMENT PROCEDURES. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Spring: > 02-3-2 > Feb > 02 > Engine Control - MIL ON, DTC P0300 or P0301 Set > Page 3008 1. Gain access to the valve springs. 2. Remove (quantity 12) existing intake and exhaust valve springs F77Z-6513-M and replace with new service intake and exhaust valve springs 2L2Z-6513-AA. NOTE ALL "12" VALVE SPRINGS ("6" INTAKE AND "6" EXHAUST) MUST BE REPLACED IN ORDER TO MAINTAIN/ENSURE PROPER VALVETRAIN DYNAMICS. 3. Road test vehicle to verify repair. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 6513 42 OASIS CODES: 499000, 608000, 609000, 6100000, 611000, 611500, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Technical Service Bulletins > Page 3009 Valve Spring: Specifications Intake Valve Spring Compression Pressure at Specified Height 202.84 - 224.968 lbf at 1.413 1.445 in Exhaust Valve Spring Compression Pressure at Specified Height 202.84 - 224.968 lbf at 1.413 1.445 in Intake Valve Spring Free Length 1.7 in Exhaust Valve Spring Free Length 1.7 in Intake Valve Spring Assembled Height 1.569 - 1.601 in Exhaust Valve Spring Assembled Height 1.569 - 1.601 in Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Technical Service Bulletins > Page 3010 Valve Spring: Service and Repair Special Tools Removal and Installation 1. Remove the camshaft roller followers. 2. Position the piston at top dead center. 3. Hold the valve in the cylinder head. - Remove the spark plugs. - Use a suitable tool to apply air pressure to the cylinder. 4. CAUTION: If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will allow the valve to fall into the cylinder. If air pressure must be removed, support the valve prior to removal. Using the special tool, remove the valve spring retainer keys, the valve spring and the retainer. 5. Inspect the components. 6. Note: Lubricate the parts with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G prior to installing. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications Valve Stem Diameter Intake 0.274 - 0.275 in Valve Stem Diameter Exhaust 0.274 in Valve Stem to Guide Clearance Exhaust 0.001 - 0.003 in Valve Stem to Guide Clearance Intake 0.001 - 0.002 in Head Diameter Intake 1.807 - 1.815 in Head Diameter Exhaust 1.531 - 1.539 in Valve Face Angle Degrees 45 deg Valve Face Runout Limit 0.001 in Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 3014 Valve: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Locations > Page 3019 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Locations > Page 3020 Drive Belt: Description and Operation The accessory drive system consists of the following: drive belt - generator - power steering pump - A/C compressor - water pump pulley - drive belt tensioner - belt idler pulley - crankshaft pulley The accessory drive: has a single serpentine drive belt (six ribs). - has an automatic tensioner. - is not adjustable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Drive Belt: Initial Inspection and Diagnostic Overview 1. Verify the customer's concern by operating the engine to duplicate the condition. 2. Inspect to determine if any of the following mechanical concerns apply: 3. Inspect for drive belt cracking/chunking/wear. 4. If the concerns remain after inspection, determine the symptoms and go to the symptom chart. Under severe operating conditions (high temperature, low humidity), drive belt rib cracking can occur at less than 96,000 km (60,000 miles). Drive belt rib cracking (cracks across grooves): is not a reason for concern. - has no detrimental effect on drive belt performance. Cracks parallel to grooves are acceptable. The drive belt is still perfectly functional until rib chunking occurs. Drive belt chunking is where the rubber material actually chunks out between the cracks. The drive belt should be replaced if chunking occurs. V-Ribbed Belt With Cracks (Acceptable) V-Ribbed Belt With Chunks Of Rib Missing (Not Acceptable) 5. If the concern(s) remains after inspection, determine the symptoms and go to the Symptom Chart. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3023 Drive Belt: Symptom Related Diagnostic Procedures 1 of 2 2 of 2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3024 Drive Belt: Component Tests and General Diagnostics Belt Tensioner The automatic drive belt tensioner can be checked as follows: 1. With the engine running, observe the drive belt tensioner movement. The drive belt tensioner should move (respond) when the A/C clutch cycles or when the engine is accelerated rapidly. If the drive belt tensioner movement is constant without A/C clutch cycling or acceleration, a pulley or shaft is probably bent or a pulley is out of round. In rare cases, excessive drive belt rideout (uneven depth of grooves in drive belt) can cause excessive drive belt tensioner movement. This condition can he checked by installing the suspect drive belt with a known good original equipment drive belt and repeating the observation. Drive Belt Misalignment CAUTION: Incorrect drive belt installation will cause excessive drive belt wear and may cause the drive belt to come off the drive pulleys. Note: Original equipment drive belts are made of a special cord construction and are subjected to special testing before they are approved for use. Non-standard new drive belts may track differently or incorrectly. If a new drive belt tracks incorrectly, install a new original equipment drive belt to avoid performance failure or loss of drive belt. With the engine running, check drive belt tracking (the position of the drive belt on one of the grooveless pulleys, idlers or drive belt tensioner. If the edge of the drive belt rides beyond the edge of the pulley, noise and premature wear may result). If a drive belt tracking condition exists, visually check the drive belt tensioner for damage, especially the mounting pad surface. If the drive belt tensioner is not installed correctly with the locating pins in the locating holes, the mounting surface pad will be out of position. This will result in abnormal drive belt tension and chirp and squeal noises. If the above procedures do not correct the drive belt noise, install a new drive belt. However, the drive belt noise may return (with mileage) if one of the above conditions still exists uncorrected. With engine running, visually observe the grooves in the pulleys (not the pulley flanges) for excessive wobble. Install new components as required. - Check all accessories, mounting brackets and drive belt tensioner, for any interference that would prevent the component from mounting properly. Correct any interference condition and recheck belt tracking. - Tighten all accessories, mounting brackets and drive belt tensioner retaining hardware to specification. Recheck drive belt tracking. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 3025 Drive Belt: Service and Repair Removal and Installation 1. Remove the air cleaner outlet tube. 2. Remove the drive belt. 1 Rotate the drive belt tensioner counterclockwise. 2 Remove the drive belt. 3. Note: Refer to Component Locations for proper drive belt routing. See: Locations To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications Drive Belt Tensioner: Specifications Drive belt tensioner bolt 30 - 40 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 3029 Drive Belt Tensioner: Service and Repair Removal and Installation 1. Remove the drive belt. 2. Remove the drive belt tensioner. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications Engine Mount: Specifications Lower engine mount bracket nuts 59 ft.lb Upper engine mount bracket nuts 81 ft.lb Lower engine mount bracket bolts 59 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Engine Mount: Service and Repair Engine Mount Removal and Installation 1. Remove the fan shroud. 2. Remove the LH engine insulator nuts. 3. Remove the RH engine insulator nuts. 4. Raise and support the vehicle. 5. Remove the LH and RH engine support insulator nuts. 6. Raise and support the engine. 7. Remove the engine support insulators. 8. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount > Page 3035 Engine Mount: Service and Repair Powertrain/Drivetrain Mount Neutralizing WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 1. Raise and Support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. Move the vehicle in forward and reverse (2 - 4 ft). CAUTION: Do not twist or strain the powertrain/drivetrain mounts. 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications Idler Pulley: Specifications Belt idler pulley bolt 30 - 40 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications > Page 3039 Idler Pulley: Service and Repair Removal and Installation 1. Remove the drive bolt. 2. Remove the belt idler pulley. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure at 2,000 rpm Hot 40-60 psi Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Specifications Engine Oil Dip Stick - Dip Stick Tube: Specifications Oil level indicator tube bracket bolt 18 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Drain Plug > Component Information > Specifications Engine Oil Drain Plug: Specifications Oil pan drain plug 19 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications Technical Service Bulletin # 02-1-9 Date: 020121 Engine Oil - Oil Recommendations/Applications Article No. 02-1-9 01/21/02 ENGINE - ENGINE OIL - RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30 MOTOR OILS - GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY FORD: 1992-2002 CROWN VICTORIA 1993-1994 TEMPO 1993-1997 THUNDERBIRD 1993-2002 ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 1998-2002 ESCORT ZX2 2000-2002 FOCUS 1993-1996 BRONCO 1993-1997 AEROSTAR 1993-2002 E SERIES, F-150, RANGER 1995-2002 WINDSTAR 1997-1999 F-250 LD 1997-2001 EXPLORER 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1991-2002 TOWN CAR 1993-1998 MARK VIII 1993-2002 CONTINENTAL 2000-2002 LS 1998-2002 NAVIGATOR MERCURY: 1992-2002 GRAND MARQUIS 1993-1994 TOPAZ 1993-1997 COUGAR 1993-1999 TRACER 1993-2002 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1997-2001 MOUNTAINEER This article is being republished in its entirety to update the vehicle models, engines and years affected. NOTE PLEASE REFER TO THE VEHICLE APPLICATION LIST LATER IN THIS TSB FOR A COMPLETE LIST OF VEHICLES AFFECTED BY THIS TSB. ISSUE Ford Motor Company now recommends SAE 5W-20 viscosity grade for servicing most gasoline and flexible fueled vehicles. ACTION All 2001 and 2002 vehicles where SAE 5W-20 is specified should be serviced at the recommended oil change intervals using SAE 5W-20. This oil is an improved formulation to improve fuel economy. Testing has validated this viscosity grade can be used in many previous model year vehicles. It is recommended ALL vehicles on the following Vehicle Application Listing be service with SAE 5W-20. All 2001-2002 vehicles other than those listed in the "Exception 2001 Vehicles" or "Exception 2002 Vehicles" chart are being filled with SAE 5W-20 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 3054 motor oil at the factory and should also be serviced with SAE 5W-20 oil. Exception 2001 Vehicles Exception 2002 Vehicles NOTE IF VEHICLE IS NOT LISTED IN THIS APPLICATION, SAE 5W-30 OIL IS RECOMMENDED. REFER TO TSB 99-8-16. Parts Block OTHER APPLICABLE ARTICLES: 99-8-16 SUPERSEDES: 01-4-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 497000, 499000 Veh. App. Listing Approved For SAE 5W-20 Motor Oil ^ 1993-1996 1.9L Escort/Tracer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 3055 ^ 1995-2000 2.0L Zetec Contour/Mystique ^ 1999-2002 2.0L Cougar ^ 1997-2002 2.0L Escort/Tracer ^ 1998-2002 2.0L Escort ZX2 ^ 2000-2002 2.0L Focus ^ 2001-2002 2.0L Escape ^ 1993-1997 2.3L Ranger ^ 1993-1994 2.3L Mustang ^ 1993-1994 2.3L Tempo/Topaz ^ 1998-2001 2.5L Ranger ^ 1995-2000 2.5L Contour/Mystique ^ 1999-2002 2.5L Cougar ^ 2001-2002 3.0L 4V Escape ^ 1996-2001 3.0L 4V Taurus/Sable ^ 1993-2002 3.0L (Vulcan) Aerostar/Ranger, ^ Taurus/Sable (Flexible Fuel and Gas) ^ 1995-2000 3.0L (Vulcan) Windstar ^ 1993-1994 3.0L (Vulcan) Tempo/Topaz ^ 2000-2002 3.0L 4V Lincoln LS ^ 1995-2002 3.8L Windstar ^ 1993-1997 3.8L Taurus/Sable, ^ Thunderbird/Cougar, Continental ^ 1994-2002 3.8L Mustang ^ 2002-2002 3.9L 4V Lincoln LS ^ 1997-2002 4.2L (SPI) F-150 (under 8500 GVW only), E-Series ^ 1996-2002 4.6L 2V Mustang ^ 1992-2002 4.6L Crown Victoria/Grand Marquis ^ 1991-2002 4.6L Town Car ^ 1994-1997 4.6L 2V Thunderbird/Cougar ^ 1996-2002 4.6L 4V Mustang Cobra ^ 1995-2002 4.6L 4V Continental ^ 1993-1998 4.6L 4V Mark VIII Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 3056 ^ 1997-2002 4.6L 2V Triton F-150/250 (under 8500 GVW only), E-Series, Expedition ^ 1993-1999 4.9L E-Series, F-Series ^ 1993-1995 5.0L Mustang/Mustang Cobra ^ 1993-1993 5.0L Thunderbird/Cougar ^ 1997-2001 5.0L Explorer/Mountaineer ^ 1993-1996 5.0L E-Series, F-Series, Bronco ^ 2000-2002 5.4L Excursion ^ 1998-2002 5.4L 2V/4V Navigator ^ 1997-2002 5.4L 2V F-1501250 (under 8500 GVW only), Expedition, E-Series, E-350 Chassis/RV/Cutaway ^ 1993-1997 5.8L F-Series, Bronco ^ 1993-1996 5.8L E-Series ^ 2000-2002 6.8L Excursion ^ 1997-2002 6.8L E-Series, E-350 Chassis/RV/Cutaway ^ 1999-2002 6.8L Super Duty F-Series 250 HD/350/450/550 Motorhome ^ 1993-1998 7.5L All Vehicles NOTE FOR 1993 THROUGH 1998 MODEL YEAR FFV USE XO-10W30-FFV. NOTE THE "EXCEPTION 2001-2002 VEHICLES" SHOULD BE SERVICED WITH SAE 5W-30 MOTOR OIL Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter ............................................................................................................................................ ............................................................. 4.7L (5.0 Qt) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 3059 Engine Oil: Fluid Type Specifications Engine Oil Type ................................................................................................................................... ............................................... SAE 5W-30 Motor Oil Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Oil bypass filter 10 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications Oil Filter Adapter: Specifications Oil filter adapter bolt 42 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 This warning message is displayed when the engine oil level is low. When the engine oil level is normal, the input to the message center indicator will be an open circuit. When the engine oil level is low, the low oil level sensor will close, grounding the input to the message center indicator and the warning will be displayed during the next ignition cycle of OFF to RUN. This low oil level sensor is only monitored when the ignition switch is OFF. There is a delay of up to 12 minutes in this monitoring in order to allow the oil to drain back into the oil pan and reach the correct level. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil pan bolts 80 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Lower Oil Pan Oil Pan: Service and Repair Lower Oil Pan Oil Pan Removal and Installation 1. Raise and support the vehicle. 2. Drain the engine oil. 3. Remove the bolts and the oil pan. 4. NOTE: All sealing surfaces must be cleaned prior to assembly. Use metal surface cleaner to clean the sealing surfaces. NOTE: Inspect integral oil pan gasket for cuts or damage that may cause leaks. Install a new gasket if necessary. NOTE: Fill the engine with clean engine oil. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Locations > Page 3077 Oil Pressure Gauge: Testing and Inspection Magnetic Gauge Testing The Instrument Gauge System Tester is used to diagnose concerns with the instrument cluster magnetic gauges. To test the magnetic gauges: ^ Disconnect the connector from the appropriate sender and connect the signal wire to the Instrument Gauge System Tester. ^ Turn the vehicle ignition switch lock cylinder to the ON position. With Instrument Gauge System Tester attached to the oil pressure switch connector and the ignition switch lock cylinder in the RUN position (engine not running), set Instrument Gauge System Tester to infinite resistance. The center line of the pointer should fall on or below the "L" mark. Short the connector directly to engine ground. The centerline of the pointer should fall slightly above mid-scale. ^ If the oil pressure gauge tests within calibration, install a new oil pressure switch. ^ If the oil pressure gauge still tests out of calibration, install a new gauge. For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil pressure sensor 9-11 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications > Page 3081 Oil Pressure Sender: Description and Operation The oil pressure switch is installed in the engine block and consists of a diaphragm and contact points. The contact points are closed with oil pressure causing the gauge to indicate NORMAL oil pressure. With no oil pressure, the contacts open and the gauge indicates low oil pressure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications > Page 3082 Oil Pressure Sender: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Additional information may also be found at Engine; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications > Page 3083 Oil Pressure Sender: Service and Repair Removal and Installation 1. Discard the battery ground cable. 2. Disconnect the oil pressure sensor electrical connector and remove the sensor. 3. Note: Coat the threads of the oil pressure sensor with Pipe Sealant with Teflon D8AZ-19554-A or Wsk-M2G350-A2. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Specifications Oil Pick Up/Strainer: Specifications Oil pump screen cover and tube bolts 8 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Specifications > Page 3087 Oil Pick Up/Strainer: Service and Repair Removal and Installation 1. Remove the oil pan. 2. Remove the oil pump screen cover and tube. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure at 2,000 rpm Hot 40-60 psi Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications Intake Manifold: Specifications Lower Intake Manifold Bolts 13 ft.lb Upper Intake manifold bolts 62 in.lb Throttle Body bolts 62 in.lb Fuel injection supply manifold bolts 18 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold: Service and Repair Lower Removal and Installation CAUTION: This vehicle is equipped with a composite material fuel supply manifold. If the supply manifold is used as a leverage device, damage may occur to the supply manifold. Care must be taken when working around the fuel supply manifold. 1. Remove the upper intake manifold. 2. Remove the lower intake manifold. - Inspect the lower intake manifold gasket and install a new one if necessary. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower > Page 3097 Intake Manifold: Service and Repair Upper Removal and Installation CAUTION: This vehicle is equipped with a composite material fuel supply manifold. If the supply manifold is used as a leverage device, damage may occur to the supply manifold. Care must be taken when working around the fuel supply manifold. 1. Disconnect the battery ground cable. 2. Remove the air cleaner outlet tube. 3. Remove the accelerator cable snow shield. 4. Disconnect the accelerator cable and speed control (if equipped) actuator cable. 1 Pull up on speed control actuator cable to remove. 2 Rotate the throttle body cam and disconnect the accelerator cable from the cam. 5. Remove and position the accelerator cable and speed control (if equipped) actuator cables aside. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower > Page 3098 6. Disconnect the RH upper intake manifold vacuum connection. 7. Disconnect the idle air control (IAC) valve electrical connector. 8. Disconnect the throttle position (TP) sensor electrical connector. 9. Disconnect the exhaust gas recirculation (EGR) vacuum regulator: - Electrical connector - Vacuum connector Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower > Page 3099 10. Disconnect the crankcase ventilation hose. 11. Disconnect the power brake booster vacuum hose. 12. Remove the eight bolts. 13. Note: Inspect and install new O-ring seals if necessary. Disconnect the LH fuel vapor management valve (VMV) hose. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower > Page 3100 14. Note: Inspect and install new O-ring seals if necessary. Disconnect the RH VMV hose. 15. Remove the upper intake manifold. - Inspect upper intake manifold gasket and install a new one if necessary. 16. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 This warning message is displayed when the engine oil level is low. When the engine oil level is normal, the input to the message center indicator will be an open circuit. When the engine oil level is low, the low oil level sensor will close, grounding the input to the message center indicator and the warning will be displayed during the next ignition cycle of OFF to RUN. This low oil level sensor is only monitored when the ignition switch is OFF. There is a delay of up to 12 minutes in this monitoring in order to allow the oil to drain back into the oil pan and reach the correct level. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Locations > Page 3108 Oil Pressure Gauge: Testing and Inspection Magnetic Gauge Testing The Instrument Gauge System Tester is used to diagnose concerns with the instrument cluster magnetic gauges. To test the magnetic gauges: ^ Disconnect the connector from the appropriate sender and connect the signal wire to the Instrument Gauge System Tester. ^ Turn the vehicle ignition switch lock cylinder to the ON position. With Instrument Gauge System Tester attached to the oil pressure switch connector and the ignition switch lock cylinder in the RUN position (engine not running), set Instrument Gauge System Tester to infinite resistance. The center line of the pointer should fall on or below the "L" mark. Short the connector directly to engine ground. The centerline of the pointer should fall slightly above mid-scale. ^ If the oil pressure gauge tests within calibration, install a new oil pressure switch. ^ If the oil pressure gauge still tests out of calibration, install a new gauge. For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Seal Special Tool(s) Material Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 3113 Removal 1. Remove the flexplate or flywheel. 2. Remove the crankshaft spacer plate. 3. Remove the crankshaft spacer. 4. CAUTION: Avoid scratching or damaging the crankshaft rear seal running surface during removal of the crankshaft rear seal. Using the special tool, remove the crankshaft rear seal. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 3114 1. NOTE: Be sure the crankshaft rear sealing surface is clean and free of any rust or corrosion. To clean the crankshaft rear seal surface area, use extra-fine emery cloth or extra-fine 0000 steel wool with metal surface prep. Lubricate the crankshaft rear seal with clean engine oil and install it on the special tool. 2. Install the special tools. 3. Position the crankshaft rear seal and the special tool. 4. Using the special tool, install the crankshaft rear seal. 5. Install the crankshaft spacer. 6. Install the spacer plate. 7. Install the flexplate or flywheel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification Cylinder Head Gasket: Technical Service Bulletins Engine - Reman Engine Head Gasket Identification TSB 06-18-16 09/18/06 IDENTIFYING THE CORRECT REPLACEMENT HEAD GASKET FOR CERTAIN REMANUFACTURED ENGINES - SERVICE TIP FORD: 1999-2006 Mustang, Mustang, Mustang, Mustang, Mustang, Mustang 2000-2005 Thunderbird 2001-2005 Taurus 2001-2006 Crown Victoria, Crown Victoria 2005 Five Hundred, Freestyle 1997-2005 Expedition 1997-2006 E-Series, Explorer, F-150, F-Super Duty 1999-2003 Windstar 1999-2004 F-53 Motorhome Chassis 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Escape, Escape, Explorer Sport Trac, Ranger 2004-2005 Freestar, Freestar 2006 F-53 Motorhome Chassis LINCOLN: 2000-2006 Lincoln LS 2001-2002 Continental 2001-200 Town Car 1998-2004 Navigator, Navigator 2003-2004 Aviator 2006 Mark LT MERCURY: 2001 Cougar 2001-2005 Sable 2001-2006 Grand Marquis 2003-2006 Marauder 2005 Montego 1997-2006 Mountaineer 2004-2005 Monterey 2005 Mariner ISSUE On various vehicles when servicing the head gasket on certain Ford remanufactured engines, it is critical to determine the type of remanufactured engine that is being serviced, in order to identify the correct replacement gasket. ACTION Follow the Service Procedure to help identify if the vehicle is equipped with a SID (for originally equipment level thickness head gasket) or OVR (for oversized service level thicker head gasket) remanufactured engine when replacing a head gasket. SERVICE PROCEDURE Use this TSB to help identify if the vehicle is equipped with a STD or OVR remanufactured engine when replacing a head gasket. This will ensure that you obtain the proper head gasket (thicker for OVR-oversized) for the engine you are repairing, as the engine may have milled engine block deck, milled cylinder head deck, or an over sized bore in the cylinders. This information will be needed when ordering parts. The parts catalogs already reflect the correct service numbers, as long as this additional information is available. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3119 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3120 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3121 For certain remanufactured engines, the long block assembly will be uniquely identified with a build date, reman code, service part number, and serial number. This metal tag will be marked with STD, or with OVR (Figures 1-6). WARRANTY STATUS: Information Only Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3122 Technical Service Bulletin # 02-1-4 Date: 020121 Engine Head Gasket - Approved Replacement Procedures Article No. 02-1-4 01/21/02 ENGINE - APPROVED HEAD GASKET REPLACEMENT SERVICE PROCEDURES FORD: 1992-1997 THUNDERBIRD 1992-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 2000-2002 FOCUS 1995-2002 WINDSTAR 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1992-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1992-1997 COUGAR 1992-1999 TRACER 1992-2002 GRAND MARQUIS, SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER ISSUE Some engine assemblies with aluminum cylinder heads repaired in-vehicle have been found to leak coolant and/or oil from the cylinder head gasket area due to particle contamination or scratches and dents at the head to block mating surfaces. ACTION Refer to the following Service Information for recommended gasket sealing surface preparation procedures. If the engine diagnosis points to a faulty head gasket (leaks oil, leaks coolant, oil or coolant contamination, or air in coolant), thorough cleaning procedures are necessary for a successful head gasket repair. Diagnosis and post-repair confirmation can be done successfully utilizing leak detection methods such as a black light dye process. SERVICE PROCEDURE To sum up, a successful leak repair depends on: ^ Accurate diagnosis of the leak using Ford-recommended test equipment and procedures ^ Surface preparation and gasket installation using the approved tools, cleaners, and methods ^ Exercising CARE and CLEANLINESS during disassembly/assembly of components ^ Use of genuine Ford OEM replacement parts ^ Use of a Ford Remanufacturer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 402000, 403000, 499000 Aluminum Cylinder Head - Removal From Engine Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3123 WARNING ALUMINUM CYLINDER HEADS ARE HIGHLY POLISHED AND MUST BE HANDLED WITH EXTREME CARE. AFTER REMOVING THE HEAD BOLTS, WITHDRAW THE HEAD FROM THE ENGINE COMPARTMENT. USE EXTREME CARE NOTING THAT THE GASKET SURFACE OF THE HEAD COULD BE DAMAGED ON THE WAY OUT OF THE VEHICLE IF ALLOWED TO HIT AGAINST OTHER ENGINE COMPONENTS. ONCE REMOVED, PLACE THE HEAD ON A BENCH, GASKET SIDE UP, USING A PIECE OF CLEAN CARDBOARD ON THE BENCH SURFACE UNDERNEATH. DO NOT SLIDE THE HEAD GASKET SURFACE ALONG THE BENCHTOP OR DAMAGE WILL OCCUR. NOTE SOME ENGINES REQUIRE A "DE-TORQUING" PROCEDURE OF THE CYLINDER HEAD BOLTS. CONSULT WITH THE APPROPRIATE MODEL YEAR WORKSHOP MANUAL FIRST, AS THIS PROCEDURE IS USUALLY DONE ON FOUR-VALVE ENGINES. HOWEVER, ALL ALUMINUM HEADS ARE PRONE TO WARPAGE DURING REMOVAL IF TAKEN OFF WHEN HOT OR WARM. THE ENGINE SHOULD BE COOLED SUFFICIENTLY BY THE TIME THE HEADS ARE ACCESSIBLE DURING TEARDOWN. ALLOW AN ADEQUATE COOL DOWN PERIOD. NOTE IN SOME ENGINE APPLICATIONS, IT MAY BE NECESSARY TO "RUBBER BAND" A FEW OF THE HEAD BOLTS TOGETHER DUE TO TIGHT CLEARANCES OF THE HEAD NEAR HEATER/AC PLENUMS AND THE BODY COWL. THIS WILL ALLOW THE BOLTS TO CLEAR THE BLOCK DECK AS THE HEAD IS WITHDRAWN FROM THE VEHICLE. Place CLEAN shop towels over the cylinder block bores to prevent further contamination from reaching internal parts and surfaces. If a towel is to be removed, do it SLOWLY . Debris collected on the towel can fall on the engine if care is not exercised as it is removed. Gasket surfaces are machined to near-mirror surface quality. Scratches, dents, gouges, and other impressions may allow oil, coolant, and compression gases to leak into other sealed cavities and/or the atmosphere. Surface imperfections deteriorate the head gasket's ability to seal effectively. Contamination on these surfaces will cause leaks from "shimming" the head even under full head bolt torque. Contamination will also cause marks on the polished gasket surface, creating a leak path. Inspection For Damage and Cleaning Procedure The overall straightness of the cylinder head and block face is held within very tight specification. Defects known as "waviness" or "depressions" cannot be surface machined out with ordinary equipment. Machining must meet manufacturer's specification on surface finish quality and be less than 0.001" inch (0.025 mm) level as measured under a known quality straightedge using a feeler gauge. If the engine has been overheated the cylinder head may have been damaged or warped. Re-surfacing will not correct this damage. The head must not contain any impressions on its sealing surface deeper than 0.001" (0.025 mm). There must not be any scratches or gouges present, especially those which track to another sealing cavity or to the atmosphere. Ensure that the mating cylinder block surface is completely free of solid contamination, corrosion, and fluids. Use Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA or equivalent, to rid the surface of any material, which could later interfere with the gasket's sealing ability. WARNING UNDER NO CIRCUMSTANCES ARE ANY ALUMINUM GASKET SURFACES TO BE CLEANED USING RAZOR BLADES, ROTARY ABRASIVE DEVICES INCLUDING ROLOC AND 3M BRANDED SCOTCHBRITE PRODUCTS, ROTARY WIRE BRUSHES, SINGLE HANDLED WIRE BRUSHES, HAND ABRASIVE SUCH AS SANDPAPER OR EMERY CLOTH, OR ANY CARBON STEEL BLADE. THESE TOOLS ARE PROVEN TO CUT AND DAMAGE ALUMINUM AND WILL DISRUPT THE POLISHED FINISH. ABRASIVE PARTICLES ARE ALSO SUSCEPTIBLE TO ENTERING THE ENGINE CAVITIES AND MAY CAUSE INTERNAL ENGINE DAMAGE. THE ONLY TOOLS ACCEPTABLE ARE PLASTIC AND WOOD SCRAPERS COMBINED WITH USE OF MOTORCRAFT METAL SURFACE CLEANER, F4AZ-19A536-RA, OR EQUIVALENT SOLVENT. The original head bolts are to be discarded. Only new head bolts are acceptable for use in a head gasket repair. Use of old bolts can cause clamp load failure because they were stretched from the last torquing procedure either from the plant or a previous field repair. The new head bolt shanks and threads should be thoroughly cleaned, dried, and lightly lubricated. Oil the bolts and let oil drip for a minimum of 5 minutes. Use of too much oil may cause hydraulic lockup in the bolt hole. The corresponding bolt holes in the cylinder block must be free of contamination consisting of dirt particles, coolant, and oil. Bolts can mechanically or hydraulically lock on top of these materials and cause for poor clamping of the cylinder head gasket. Use very lightly compressed air to blow out the bolt holes. Use care to prevent debris from scattering over the internal engine surfaces. To clean the cylinder block gasket surface, a plastic or wood scraper in combination with Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent can be used with a portable shop vacuum. Move the scraper toward the vacuum nozzle to direct loosened material quickly away from the block surface. It is not necessary to expect aluminum head surfaces to be shiny and bright after the vehicle has been in service. Sanding, scraping, or polishing will create surface depressions that cause leaks. The surface is expected to be flat within 0.001" (0.025 mm) and free of dirt, metal chips, and liquid contaminants. Any staining of the metal surface is considered normal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3124 Machining of aluminum heads and blocks is an unacceptable field practice for quality control purposes of flatness and surface finish standards. Removing material will also raise the risk of internal reciprocating components striking each other, as well as changing the emissions calibration of the engine. Machining practices of aluminum blocks and heads are not reimbursable. Ford Remanufacturers are authorized to perform this procedure and have the necessary equipment to put the specified surface finish on the head within original factory limits. Installation Onto the Cylinder Block Surface WARNING ANY GASKET SEALING AIDS WHICH ARE NOT LIMITED TO, AND INCLUDE AVIATION CEMENT, COPPER SPRAYS, OR GLUES ARE NOT TO BE USED. THE GASKET MUST BE FITTED DRY WITHOUT SUPPLEMENTAL SEALING AIDS. ATTEMPTS TO SEAL WITH THESE COMPOUNDS WILL CAUSE HEAD SHIMMING AND/OR NEW LEAK PATHS. THESE COMPOUNDS HAVE ALSO BEEN KNOWN TO CAUSE EMISSIONS SENSORS TO FAIL THEREBY TRIPPING FAULT CODES IN THE PCM. Ensure that all surfaces of the cylinder block, cylinder head, and gasket are fully free of any solid or liquid contamination and have been prepared for assembly using Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent. Also ensure that any residual dirt on the engine was removed successfully from the surrounding areas of the block to head face of the head and the block. Using Workshop Manual procedures, assemble the head to the block carefully. Do not allow the gasket surfaces to scrape or bang against other engine parts. The head may pick up material along the way, if this is allowed. Once in place, with dowels properly aligned to the head and ensuring that the head is fully square, seated, and resting on the block deck in a level condition, install new "torque-to-yield" cylinder head bolts to a finger tight condition. Refer to the appropriate model year Workshop Manual for the procedure to torque the head bolts in the correct sequence and at the intervals specified. Failure to follow these instructions may result in a warped head, and damaged head bolt threads. Do not use "cheater pipes" on torque wrenches. Use a known quality, calibrated torque wrench. Pull evenly and steady on each bolt. Do not exert side pressures on the bolt hex, which can disrupt the integrity of the bolt head and give a false reading on the final torque value of the fastener. Once the engine is fully reassembled, be sure that fluid levels have been topped off as required for the operation. When the engine is ready for starting, ensure that the engine 6i1 pump is (was) primed properly and is in a "ready to start" condition with all engine oil galleys having been charged with oil. WARNING DO NOT RACE THE ENGINE UPON INITIAL STARTUP. MAINTAIN ENGINE IDLE TO BUILD OIL PRESSURE. USE OF A MECHANICAL PRESSURE GAUGE WILL ENSURE THAT OIL FLOW HAS DEVELOPED ON THE PUMP'S PRESSURE SIDE. A DEFECTIVE GAUGE OR LIGHT IN THE INSTRUMENT PANEL WILL NOT VERIFY PRESSURE HAS BEEN OBTAINED. SEVERE INTERNAL ENGINE DAMAGE WILL RESULT IF PRESSURE IS NOT OBSERVED AND STEADILY MAINTAINED. Allow a warm up period, which brings the engine to normal operating temperature. Check for leaks around the gasket joints of the head, front cover, and associated component parts. The vehicle should be road tested within normal guidelines to raise the engine to operating temperature and verify the repair is sound. Shut down the engine, allow for a cool-down and drain-back period to enable fluids to return to levels. Check fluid levels using owner guide recommendations (dipstick, sight gages, etc.). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair Special Tools Removal 1. Remove the crankshaft pulley. 2. Using the special tool, remove the crankshaft front oil seal. Installation 1. Note: Lubricate the seal lip with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Using the special tools and install the crankshaft front oil seal. 2. Install the crankshaft pulley. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket Technical Service Bulletin # 00M12 Date: 001101 Campaign - Camshaft Chain Tensioner & Intake Gasket 00M12 OWNER NOTIFICATION PROGRAM Certain 1997 through 2000 Explorer/Mountaineer and 2001 Explorer Sport/Sport-Trac Vehicles Equipped with 4.0L SOHC Engines - Camshaft Chain Tensioner and Lower Intake Manifold Gasket Additional Coverage ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Questions & Answer Sheet ^ Customer Notification Letter Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3136 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3137 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. NOTE: When a claim is submitted on an "M" program the VIN number will remain in OASIS until the terms of the program expire. CLAIMS PREPARATION AND SUBMISSION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3138 ^ Enter claims using DWE. ^ Refer to ACESII Manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company will only refund the cost of repairs for the camshaft chain tensioner and/or lower intake manifold gaskets 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). To qualify for the refund, the camshaft chain tensioner and/or lower intake manifold gasket must have been the causal part for the repair. All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII Manual for Refund information. Enter claims using DWE: Program Code: 00M12 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels as noted below: DOR/COR NUMBER DOR/COR for this program is 50196 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3139 DEALER PRICE For latest prices, check or call your: ^ 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. Attachment III - Technical Information OVERVIEW While performing this procedure the technician will install a: ^ New upper and lower intake manifold gaskets. ^ New cam chain tensioner and washer. ^ Volume reduction plug into the left cylinder head oil galley. ^ New oil galley plug. IMPORTANT TIME SAVING REPAIR TIPS ^ Always use a hand impact driver with a short extension when loosening the oil galley plug. Be sure the T-30 Torx(R) bit is in good condition, and that there is no foreign material inside the plug which would prevent the bit from fully seating. The plug may be seized on some higher mileage vehicles, and not seating the bit may cause the bit to damage the plug. ^ Before removing the engine coolant temperature sensor, relieve any residual cooling system pressure by removing the radiator cap and then reinstalling it. Doing this will allow you to remove the sensor without having to drain the cooling system. ^ During assembly, DO NOT use any silicone products as they may cause damage to the oxygen sensors. ^ Allow the engine and cooling system to cool down prior to beginning this repair. Question -- Are these procedures the same as related procedures found in TSBs or in the Workshop Manual? Answer -- No. If you follow the procedures in this set of instructions, you will not need to disconnect the battery or install a memory saver, or drain and refill the cooling system. Also, this procedure involves removal of the upper and lower intake manifolds to replace the gaskets. Once the manifolds and the ECT are removed, the oil galley plug and the cam tensioner are easily accessed. LOWER INTAKE MANIFOLD REMOVAL 1. Remove the accelerator control splash shield. 2. Disconnect the speed control and accelerator cables from the throttle body control lever and the upper intake manifold. 3. Disconnect the intake air temperature (IAT) sensor. 4. Disconnect the fresh air tubes from the air cleaner outlet tube, then remove the air cleaner outlet tube. 5. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3140 6. Disconnect the following vacuum hoses: See Figures 1 and 2. ^ Brake booster. ^ Intake manifold tuning valve (IMTV) servo, if equipped. ^ Right side upper intake vacuum supply (two hoses). ^ PCV valve. 7. Remove the fasteners securing the EVR/VIS solenoid bracket. It is not necessary to disconnect the solenoids. Refer to Figure 2. 8. Remove the upper intake manifold screws. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3141 9. Lift up the upper intake manifold to access the vapor management valve (VMV) hoses. Remove the locking clips and disconnect the right and left VMV hoses. See Figure 3. 10. Remove the upper intake manifold by carefully sliding the manifold off of the exhaust gas recirculation (EGR) tube. See Figure 3. 11. If equipped, position the engine vacuum reservoir aside. See Figure 4. 12. Remove the lower intake manifold. See Figure 4. CAUTION: The intake ports of the cylinder heads must be covered to avoid any foreign material from entering the engine. 13. Clean all foreign material from the intake manifold/cylinder head area, then cover the cylinder head ports with clean shop towels. VOLUME REDUCTION PLUG AND CAM CHAIN TENSIONER REPLACEMENT Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3142 1. Disconnect the engine coolant temperature (ECT) sensor and the engine coolant temperature sender. Position the wiring harness connectors away from the oil galley plug area. See Figure 5. CAUTION: Damage to the oil galley plug will occur if the Torx(R) bit is not fully seated. Use a hand impact driver and an extension, striking the driver firmly, to loosen the plug. 2. Remove the oil galley plug. See Figure 5. 3. Install the volume reduction plug into the oil galley. See Figure 6. CAUTION: Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3143 The new oil galley plug comes pre-encapsulated with sealant. Do not apply additional sealant to the plug. 4. Install the new oil galley plug. Tighten the plug until it is flush with the face of the cylinder head. NOTE: Failure to remove then reinstall the radiator cap may result in coolant draining when the engine coolant temperature (ECT) sensor is removed. 5. Remove, then reinstall, the radiator cap. 6. Remove the ECT sensor only. See Figure 5. 7. Remove and discard the left cam chain tensioner and washer. See Figure 5. 8. Install the new cam chain tensioner and washer. Tighten the tensioner to 44 Nm (32 lb-ft). See Figure 7. 9. Install and connect the ECT sensor. Tighten the sensor to 15 Nm (132 lb-in). 10. Connect the coolant temperature sender. LOWER INTAKE MANIFOLD -- INSTALLATION 1. Remove the old gaskets from the lower intake manifold. Clean the manifold gasket mating surfaces. Remove the shop towels from the cylinder heads and clean the gasket mating surfaces. 2. Install new lower intake manifold gaskets, making sure they are correctly seated. 3. Install the lower intake manifold. Tighten the bolts to 18 Nm (13 lb-ft). 4. Install the engine vacuum reservoir, if equipped. 5. Install the locking clips onto the right and left VMV hose connectors. 6. Install the new upper intake manifold gaskets. CAUTION: When installing the upper intake manifold, be sure that all vacuum lines are positioned back to avoid pinching them under the manifold. CAUTION: DO Not use any silicone-based lubricants on the EGR tube 0-ring. NOTE: Using Penetrating and Lock Lubricant, E8AZ-19A501-B or equivalent non-silicone-based lubricant, lightly lubricate the EGR tube 0-ring to allow Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3144 for easier installation of the upper intake manifold. 7. Position the upper intake manifold carefully, slide the manifold onto the EGR tube and connect both right and left VMV hoses. Also, be sure to route the IAC valve connector into position. 8. Install the upper intake manifold screws. Tighten the screws to 7 Nm (62 lb-in). 9. Connect the IAC valve and TPS connector. 10. Install the EVR/VIS solenoid bracket. Tighten the screws to 3 Nm (26 lb-in). 11. Connect the following vacuum hoses: ^ Brake booster. ^ Intake manifold tuning valve (IMTV) servo, if equipped. ^ Right side upper intake vacuum supply (two hoses). ^ PCV valve. 12. Install the air cleaner outlet tube, and connect the fresh air tubes and IAT sensor. 13. Correctly route and secure the accelerator and speed control cables. Tighten the screws to 3 Nm (26 lb-in). 14. Install the accelerator control splash shield. 15. Start the engine and check for correct operation. Check and top off the cooling system as needed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3145 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3146 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3147 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket Technical Service Bulletin # 00M12 Date: 001101 Campaign - Camshaft Chain Tensioner & Intake Gasket 00M12 OWNER NOTIFICATION PROGRAM Certain 1997 through 2000 Explorer/Mountaineer and 2001 Explorer Sport/Sport-Trac Vehicles Equipped with 4.0L SOHC Engines - Camshaft Chain Tensioner and Lower Intake Manifold Gasket Additional Coverage ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Questions & Answer Sheet ^ Customer Notification Letter Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3153 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3154 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. NOTE: When a claim is submitted on an "M" program the VIN number will remain in OASIS until the terms of the program expire. CLAIMS PREPARATION AND SUBMISSION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3155 ^ Enter claims using DWE. ^ Refer to ACESII Manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company will only refund the cost of repairs for the camshaft chain tensioner and/or lower intake manifold gaskets 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). To qualify for the refund, the camshaft chain tensioner and/or lower intake manifold gasket must have been the causal part for the repair. All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII Manual for Refund information. Enter claims using DWE: Program Code: 00M12 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels as noted below: DOR/COR NUMBER DOR/COR for this program is 50196 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3156 DEALER PRICE For latest prices, check or call your: ^ 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. Attachment III - Technical Information OVERVIEW While performing this procedure the technician will install a: ^ New upper and lower intake manifold gaskets. ^ New cam chain tensioner and washer. ^ Volume reduction plug into the left cylinder head oil galley. ^ New oil galley plug. IMPORTANT TIME SAVING REPAIR TIPS ^ Always use a hand impact driver with a short extension when loosening the oil galley plug. Be sure the T-30 Torx(R) bit is in good condition, and that there is no foreign material inside the plug which would prevent the bit from fully seating. The plug may be seized on some higher mileage vehicles, and not seating the bit may cause the bit to damage the plug. ^ Before removing the engine coolant temperature sensor, relieve any residual cooling system pressure by removing the radiator cap and then reinstalling it. Doing this will allow you to remove the sensor without having to drain the cooling system. ^ During assembly, DO NOT use any silicone products as they may cause damage to the oxygen sensors. ^ Allow the engine and cooling system to cool down prior to beginning this repair. Question -- Are these procedures the same as related procedures found in TSBs or in the Workshop Manual? Answer -- No. If you follow the procedures in this set of instructions, you will not need to disconnect the battery or install a memory saver, or drain and refill the cooling system. Also, this procedure involves removal of the upper and lower intake manifolds to replace the gaskets. Once the manifolds and the ECT are removed, the oil galley plug and the cam tensioner are easily accessed. LOWER INTAKE MANIFOLD REMOVAL 1. Remove the accelerator control splash shield. 2. Disconnect the speed control and accelerator cables from the throttle body control lever and the upper intake manifold. 3. Disconnect the intake air temperature (IAT) sensor. 4. Disconnect the fresh air tubes from the air cleaner outlet tube, then remove the air cleaner outlet tube. 5. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3157 6. Disconnect the following vacuum hoses: See Figures 1 and 2. ^ Brake booster. ^ Intake manifold tuning valve (IMTV) servo, if equipped. ^ Right side upper intake vacuum supply (two hoses). ^ PCV valve. 7. Remove the fasteners securing the EVR/VIS solenoid bracket. It is not necessary to disconnect the solenoids. Refer to Figure 2. 8. Remove the upper intake manifold screws. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3158 9. Lift up the upper intake manifold to access the vapor management valve (VMV) hoses. Remove the locking clips and disconnect the right and left VMV hoses. See Figure 3. 10. Remove the upper intake manifold by carefully sliding the manifold off of the exhaust gas recirculation (EGR) tube. See Figure 3. 11. If equipped, position the engine vacuum reservoir aside. See Figure 4. 12. Remove the lower intake manifold. See Figure 4. CAUTION: The intake ports of the cylinder heads must be covered to avoid any foreign material from entering the engine. 13. Clean all foreign material from the intake manifold/cylinder head area, then cover the cylinder head ports with clean shop towels. VOLUME REDUCTION PLUG AND CAM CHAIN TENSIONER REPLACEMENT Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3159 1. Disconnect the engine coolant temperature (ECT) sensor and the engine coolant temperature sender. Position the wiring harness connectors away from the oil galley plug area. See Figure 5. CAUTION: Damage to the oil galley plug will occur if the Torx(R) bit is not fully seated. Use a hand impact driver and an extension, striking the driver firmly, to loosen the plug. 2. Remove the oil galley plug. See Figure 5. 3. Install the volume reduction plug into the oil galley. See Figure 6. CAUTION: Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3160 The new oil galley plug comes pre-encapsulated with sealant. Do not apply additional sealant to the plug. 4. Install the new oil galley plug. Tighten the plug until it is flush with the face of the cylinder head. NOTE: Failure to remove then reinstall the radiator cap may result in coolant draining when the engine coolant temperature (ECT) sensor is removed. 5. Remove, then reinstall, the radiator cap. 6. Remove the ECT sensor only. See Figure 5. 7. Remove and discard the left cam chain tensioner and washer. See Figure 5. 8. Install the new cam chain tensioner and washer. Tighten the tensioner to 44 Nm (32 lb-ft). See Figure 7. 9. Install and connect the ECT sensor. Tighten the sensor to 15 Nm (132 lb-in). 10. Connect the coolant temperature sender. LOWER INTAKE MANIFOLD -- INSTALLATION 1. Remove the old gaskets from the lower intake manifold. Clean the manifold gasket mating surfaces. Remove the shop towels from the cylinder heads and clean the gasket mating surfaces. 2. Install new lower intake manifold gaskets, making sure they are correctly seated. 3. Install the lower intake manifold. Tighten the bolts to 18 Nm (13 lb-ft). 4. Install the engine vacuum reservoir, if equipped. 5. Install the locking clips onto the right and left VMV hose connectors. 6. Install the new upper intake manifold gaskets. CAUTION: When installing the upper intake manifold, be sure that all vacuum lines are positioned back to avoid pinching them under the manifold. CAUTION: DO Not use any silicone-based lubricants on the EGR tube 0-ring. NOTE: Using Penetrating and Lock Lubricant, E8AZ-19A501-B or equivalent non-silicone-based lubricant, lightly lubricate the EGR tube 0-ring to allow Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3161 for easier installation of the upper intake manifold. 7. Position the upper intake manifold carefully, slide the manifold onto the EGR tube and connect both right and left VMV hoses. Also, be sure to route the IAC valve connector into position. 8. Install the upper intake manifold screws. Tighten the screws to 7 Nm (62 lb-in). 9. Connect the IAC valve and TPS connector. 10. Install the EVR/VIS solenoid bracket. Tighten the screws to 3 Nm (26 lb-in). 11. Connect the following vacuum hoses: ^ Brake booster. ^ Intake manifold tuning valve (IMTV) servo, if equipped. ^ Right side upper intake vacuum supply (two hoses). ^ PCV valve. 12. Install the air cleaner outlet tube, and connect the fresh air tubes and IAT sensor. 13. Correctly route and secure the accelerator and speed control cables. Tighten the screws to 3 Nm (26 lb-in). 14. Install the accelerator control splash shield. 15. Start the engine and check for correct operation. Check and top off the cooling system as needed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3162 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3163 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3164 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair Valve Guide Seal: Service and Repair Special Tools Removal 1. Remove the valve springs. 2. Remove the valve stem seals. Installation 1. Note: Lubricate parts with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G prior to installing. Using the special tool, install the valve stem seals. 2. Install the valve springs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil pressure sensor 9-11 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 3172 Oil Pressure Sender: Description and Operation The oil pressure switch is installed in the engine block and consists of a diaphragm and contact points. The contact points are closed with oil pressure causing the gauge to indicate NORMAL oil pressure. With no oil pressure, the contacts open and the gauge indicates low oil pressure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 3173 Oil Pressure Sender: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Additional information may also be found at Engine; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 3174 Oil Pressure Sender: Service and Repair Removal and Installation 1. Discard the battery ground cable. 2. Disconnect the oil pressure sensor electrical connector and remove the sensor. 3. Note: Coat the threads of the oil pressure sensor with Pipe Sealant with Teflon D8AZ-19554-A or Wsk-M2G350-A2. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Specifications Balance Shaft: Specifications Balance shaft bolts 19 - 21 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft Chain Guide > Component Information > Specifications Balance Shaft Chain Guide: Specifications Balance shaft chain guide 80 - 97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft Chain Tensioner > Component Information > Specifications Balance Shaft Chain Tensioner: Specifications Balance shaft tensioner bolts 21 - 22 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications > Camshaft Gear/Sprocket Camshaft Gear/Sprocket: Specifications Camshaft sprocket bolt 63 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications > Camshaft Gear/Sprocket > Page 3189 Camshaft Gear/Sprocket: Specifications Camshaft Sprocket Bolt 63 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket Technical Service Bulletin # 00M12 Date: 001101 Campaign - Camshaft Chain Tensioner & Intake Gasket 00M12 OWNER NOTIFICATION PROGRAM Certain 1997 through 2000 Explorer/Mountaineer and 2001 Explorer Sport/Sport-Trac Vehicles Equipped with 4.0L SOHC Engines - Camshaft Chain Tensioner and Lower Intake Manifold Gasket Additional Coverage ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Questions & Answer Sheet ^ Customer Notification Letter Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3198 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3199 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. NOTE: When a claim is submitted on an "M" program the VIN number will remain in OASIS until the terms of the program expire. CLAIMS PREPARATION AND SUBMISSION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3200 ^ Enter claims using DWE. ^ Refer to ACESII Manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company will only refund the cost of repairs for the camshaft chain tensioner and/or lower intake manifold gaskets 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). To qualify for the refund, the camshaft chain tensioner and/or lower intake manifold gasket must have been the causal part for the repair. All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII Manual for Refund information. Enter claims using DWE: Program Code: 00M12 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels as noted below: DOR/COR NUMBER DOR/COR for this program is 50196 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3201 DEALER PRICE For latest prices, check or call your: ^ 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. Attachment III - Technical Information OVERVIEW While performing this procedure the technician will install a: ^ New upper and lower intake manifold gaskets. ^ New cam chain tensioner and washer. ^ Volume reduction plug into the left cylinder head oil galley. ^ New oil galley plug. IMPORTANT TIME SAVING REPAIR TIPS ^ Always use a hand impact driver with a short extension when loosening the oil galley plug. Be sure the T-30 Torx(R) bit is in good condition, and that there is no foreign material inside the plug which would prevent the bit from fully seating. The plug may be seized on some higher mileage vehicles, and not seating the bit may cause the bit to damage the plug. ^ Before removing the engine coolant temperature sensor, relieve any residual cooling system pressure by removing the radiator cap and then reinstalling it. Doing this will allow you to remove the sensor without having to drain the cooling system. ^ During assembly, DO NOT use any silicone products as they may cause damage to the oxygen sensors. ^ Allow the engine and cooling system to cool down prior to beginning this repair. Question -- Are these procedures the same as related procedures found in TSBs or in the Workshop Manual? Answer -- No. If you follow the procedures in this set of instructions, you will not need to disconnect the battery or install a memory saver, or drain and refill the cooling system. Also, this procedure involves removal of the upper and lower intake manifolds to replace the gaskets. Once the manifolds and the ECT are removed, the oil galley plug and the cam tensioner are easily accessed. LOWER INTAKE MANIFOLD REMOVAL 1. Remove the accelerator control splash shield. 2. Disconnect the speed control and accelerator cables from the throttle body control lever and the upper intake manifold. 3. Disconnect the intake air temperature (IAT) sensor. 4. Disconnect the fresh air tubes from the air cleaner outlet tube, then remove the air cleaner outlet tube. 5. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3202 6. Disconnect the following vacuum hoses: See Figures 1 and 2. ^ Brake booster. ^ Intake manifold tuning valve (IMTV) servo, if equipped. ^ Right side upper intake vacuum supply (two hoses). ^ PCV valve. 7. Remove the fasteners securing the EVR/VIS solenoid bracket. It is not necessary to disconnect the solenoids. Refer to Figure 2. 8. Remove the upper intake manifold screws. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3203 9. Lift up the upper intake manifold to access the vapor management valve (VMV) hoses. Remove the locking clips and disconnect the right and left VMV hoses. See Figure 3. 10. Remove the upper intake manifold by carefully sliding the manifold off of the exhaust gas recirculation (EGR) tube. See Figure 3. 11. If equipped, position the engine vacuum reservoir aside. See Figure 4. 12. Remove the lower intake manifold. See Figure 4. CAUTION: The intake ports of the cylinder heads must be covered to avoid any foreign material from entering the engine. 13. Clean all foreign material from the intake manifold/cylinder head area, then cover the cylinder head ports with clean shop towels. VOLUME REDUCTION PLUG AND CAM CHAIN TENSIONER REPLACEMENT Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3204 1. Disconnect the engine coolant temperature (ECT) sensor and the engine coolant temperature sender. Position the wiring harness connectors away from the oil galley plug area. See Figure 5. CAUTION: Damage to the oil galley plug will occur if the Torx(R) bit is not fully seated. Use a hand impact driver and an extension, striking the driver firmly, to loosen the plug. 2. Remove the oil galley plug. See Figure 5. 3. Install the volume reduction plug into the oil galley. See Figure 6. CAUTION: Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3205 The new oil galley plug comes pre-encapsulated with sealant. Do not apply additional sealant to the plug. 4. Install the new oil galley plug. Tighten the plug until it is flush with the face of the cylinder head. NOTE: Failure to remove then reinstall the radiator cap may result in coolant draining when the engine coolant temperature (ECT) sensor is removed. 5. Remove, then reinstall, the radiator cap. 6. Remove the ECT sensor only. See Figure 5. 7. Remove and discard the left cam chain tensioner and washer. See Figure 5. 8. Install the new cam chain tensioner and washer. Tighten the tensioner to 44 Nm (32 lb-ft). See Figure 7. 9. Install and connect the ECT sensor. Tighten the sensor to 15 Nm (132 lb-in). 10. Connect the coolant temperature sender. LOWER INTAKE MANIFOLD -- INSTALLATION 1. Remove the old gaskets from the lower intake manifold. Clean the manifold gasket mating surfaces. Remove the shop towels from the cylinder heads and clean the gasket mating surfaces. 2. Install new lower intake manifold gaskets, making sure they are correctly seated. 3. Install the lower intake manifold. Tighten the bolts to 18 Nm (13 lb-ft). 4. Install the engine vacuum reservoir, if equipped. 5. Install the locking clips onto the right and left VMV hose connectors. 6. Install the new upper intake manifold gaskets. CAUTION: When installing the upper intake manifold, be sure that all vacuum lines are positioned back to avoid pinching them under the manifold. CAUTION: DO Not use any silicone-based lubricants on the EGR tube 0-ring. NOTE: Using Penetrating and Lock Lubricant, E8AZ-19A501-B or equivalent non-silicone-based lubricant, lightly lubricate the EGR tube 0-ring to allow Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3206 for easier installation of the upper intake manifold. 7. Position the upper intake manifold carefully, slide the manifold onto the EGR tube and connect both right and left VMV hoses. Also, be sure to route the IAC valve connector into position. 8. Install the upper intake manifold screws. Tighten the screws to 7 Nm (62 lb-in). 9. Connect the IAC valve and TPS connector. 10. Install the EVR/VIS solenoid bracket. Tighten the screws to 3 Nm (26 lb-in). 11. Connect the following vacuum hoses: ^ Brake booster. ^ Intake manifold tuning valve (IMTV) servo, if equipped. ^ Right side upper intake vacuum supply (two hoses). ^ PCV valve. 12. Install the air cleaner outlet tube, and connect the fresh air tubes and IAT sensor. 13. Correctly route and secure the accelerator and speed control cables. Tighten the screws to 3 Nm (26 lb-in). 14. Install the accelerator control splash shield. 15. Start the engine and check for correct operation. Check and top off the cooling system as needed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3207 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3208 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3209 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket Technical Service Bulletin # 00M12 Date: 001101 Campaign - Camshaft Chain Tensioner & Intake Gasket 00M12 OWNER NOTIFICATION PROGRAM Certain 1997 through 2000 Explorer/Mountaineer and 2001 Explorer Sport/Sport-Trac Vehicles Equipped with 4.0L SOHC Engines - Camshaft Chain Tensioner and Lower Intake Manifold Gasket Additional Coverage ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Questions & Answer Sheet ^ Customer Notification Letter Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3215 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3216 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. NOTE: When a claim is submitted on an "M" program the VIN number will remain in OASIS until the terms of the program expire. CLAIMS PREPARATION AND SUBMISSION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3217 ^ Enter claims using DWE. ^ Refer to ACESII Manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company will only refund the cost of repairs for the camshaft chain tensioner and/or lower intake manifold gaskets 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). To qualify for the refund, the camshaft chain tensioner and/or lower intake manifold gasket must have been the causal part for the repair. All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII Manual for Refund information. Enter claims using DWE: Program Code: 00M12 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels as noted below: DOR/COR NUMBER DOR/COR for this program is 50196 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3218 DEALER PRICE For latest prices, check or call your: ^ 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. Attachment III - Technical Information OVERVIEW While performing this procedure the technician will install a: ^ New upper and lower intake manifold gaskets. ^ New cam chain tensioner and washer. ^ Volume reduction plug into the left cylinder head oil galley. ^ New oil galley plug. IMPORTANT TIME SAVING REPAIR TIPS ^ Always use a hand impact driver with a short extension when loosening the oil galley plug. Be sure the T-30 Torx(R) bit is in good condition, and that there is no foreign material inside the plug which would prevent the bit from fully seating. The plug may be seized on some higher mileage vehicles, and not seating the bit may cause the bit to damage the plug. ^ Before removing the engine coolant temperature sensor, relieve any residual cooling system pressure by removing the radiator cap and then reinstalling it. Doing this will allow you to remove the sensor without having to drain the cooling system. ^ During assembly, DO NOT use any silicone products as they may cause damage to the oxygen sensors. ^ Allow the engine and cooling system to cool down prior to beginning this repair. Question -- Are these procedures the same as related procedures found in TSBs or in the Workshop Manual? Answer -- No. If you follow the procedures in this set of instructions, you will not need to disconnect the battery or install a memory saver, or drain and refill the cooling system. Also, this procedure involves removal of the upper and lower intake manifolds to replace the gaskets. Once the manifolds and the ECT are removed, the oil galley plug and the cam tensioner are easily accessed. LOWER INTAKE MANIFOLD REMOVAL 1. Remove the accelerator control splash shield. 2. Disconnect the speed control and accelerator cables from the throttle body control lever and the upper intake manifold. 3. Disconnect the intake air temperature (IAT) sensor. 4. Disconnect the fresh air tubes from the air cleaner outlet tube, then remove the air cleaner outlet tube. 5. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3219 6. Disconnect the following vacuum hoses: See Figures 1 and 2. ^ Brake booster. ^ Intake manifold tuning valve (IMTV) servo, if equipped. ^ Right side upper intake vacuum supply (two hoses). ^ PCV valve. 7. Remove the fasteners securing the EVR/VIS solenoid bracket. It is not necessary to disconnect the solenoids. Refer to Figure 2. 8. Remove the upper intake manifold screws. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3220 9. Lift up the upper intake manifold to access the vapor management valve (VMV) hoses. Remove the locking clips and disconnect the right and left VMV hoses. See Figure 3. 10. Remove the upper intake manifold by carefully sliding the manifold off of the exhaust gas recirculation (EGR) tube. See Figure 3. 11. If equipped, position the engine vacuum reservoir aside. See Figure 4. 12. Remove the lower intake manifold. See Figure 4. CAUTION: The intake ports of the cylinder heads must be covered to avoid any foreign material from entering the engine. 13. Clean all foreign material from the intake manifold/cylinder head area, then cover the cylinder head ports with clean shop towels. VOLUME REDUCTION PLUG AND CAM CHAIN TENSIONER REPLACEMENT Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3221 1. Disconnect the engine coolant temperature (ECT) sensor and the engine coolant temperature sender. Position the wiring harness connectors away from the oil galley plug area. See Figure 5. CAUTION: Damage to the oil galley plug will occur if the Torx(R) bit is not fully seated. Use a hand impact driver and an extension, striking the driver firmly, to loosen the plug. 2. Remove the oil galley plug. See Figure 5. 3. Install the volume reduction plug into the oil galley. See Figure 6. CAUTION: Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3222 The new oil galley plug comes pre-encapsulated with sealant. Do not apply additional sealant to the plug. 4. Install the new oil galley plug. Tighten the plug until it is flush with the face of the cylinder head. NOTE: Failure to remove then reinstall the radiator cap may result in coolant draining when the engine coolant temperature (ECT) sensor is removed. 5. Remove, then reinstall, the radiator cap. 6. Remove the ECT sensor only. See Figure 5. 7. Remove and discard the left cam chain tensioner and washer. See Figure 5. 8. Install the new cam chain tensioner and washer. Tighten the tensioner to 44 Nm (32 lb-ft). See Figure 7. 9. Install and connect the ECT sensor. Tighten the sensor to 15 Nm (132 lb-in). 10. Connect the coolant temperature sender. LOWER INTAKE MANIFOLD -- INSTALLATION 1. Remove the old gaskets from the lower intake manifold. Clean the manifold gasket mating surfaces. Remove the shop towels from the cylinder heads and clean the gasket mating surfaces. 2. Install new lower intake manifold gaskets, making sure they are correctly seated. 3. Install the lower intake manifold. Tighten the bolts to 18 Nm (13 lb-ft). 4. Install the engine vacuum reservoir, if equipped. 5. Install the locking clips onto the right and left VMV hose connectors. 6. Install the new upper intake manifold gaskets. CAUTION: When installing the upper intake manifold, be sure that all vacuum lines are positioned back to avoid pinching them under the manifold. CAUTION: DO Not use any silicone-based lubricants on the EGR tube 0-ring. NOTE: Using Penetrating and Lock Lubricant, E8AZ-19A501-B or equivalent non-silicone-based lubricant, lightly lubricate the EGR tube 0-ring to allow Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3223 for easier installation of the upper intake manifold. 7. Position the upper intake manifold carefully, slide the manifold onto the EGR tube and connect both right and left VMV hoses. Also, be sure to route the IAC valve connector into position. 8. Install the upper intake manifold screws. Tighten the screws to 7 Nm (62 lb-in). 9. Connect the IAC valve and TPS connector. 10. Install the EVR/VIS solenoid bracket. Tighten the screws to 3 Nm (26 lb-in). 11. Connect the following vacuum hoses: ^ Brake booster. ^ Intake manifold tuning valve (IMTV) servo, if equipped. ^ Right side upper intake vacuum supply (two hoses). ^ PCV valve. 12. Install the air cleaner outlet tube, and connect the fresh air tubes and IAT sensor. 13. Correctly route and secure the accelerator and speed control cables. Tighten the screws to 3 Nm (26 lb-in). 14. Install the accelerator control splash shield. 15. Start the engine and check for correct operation. Check and top off the cooling system as needed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3224 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3225 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3226 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Specifications Timing Chain Guide: Specifications Jackshaft chain guide bolts 14 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket Technical Service Bulletin # 00M12 Date: 001101 Campaign - Camshaft Chain Tensioner & Intake Gasket 00M12 OWNER NOTIFICATION PROGRAM Certain 1997 through 2000 Explorer/Mountaineer and 2001 Explorer Sport/Sport-Trac Vehicles Equipped with 4.0L SOHC Engines - Camshaft Chain Tensioner and Lower Intake Manifold Gasket Additional Coverage ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Questions & Answer Sheet ^ Customer Notification Letter Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3238 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3239 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. NOTE: When a claim is submitted on an "M" program the VIN number will remain in OASIS until the terms of the program expire. CLAIMS PREPARATION AND SUBMISSION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3240 ^ Enter claims using DWE. ^ Refer to ACESII Manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company will only refund the cost of repairs for the camshaft chain tensioner and/or lower intake manifold gaskets 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). To qualify for the refund, the camshaft chain tensioner and/or lower intake manifold gasket must have been the causal part for the repair. All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII Manual for Refund information. Enter claims using DWE: Program Code: 00M12 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels as noted below: DOR/COR NUMBER DOR/COR for this program is 50196 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3241 DEALER PRICE For latest prices, check or call your: ^ 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. Attachment III - Technical Information OVERVIEW While performing this procedure the technician will install a: ^ New upper and lower intake manifold gaskets. ^ New cam chain tensioner and washer. ^ Volume reduction plug into the left cylinder head oil galley. ^ New oil galley plug. IMPORTANT TIME SAVING REPAIR TIPS ^ Always use a hand impact driver with a short extension when loosening the oil galley plug. Be sure the T-30 Torx(R) bit is in good condition, and that there is no foreign material inside the plug which would prevent the bit from fully seating. The plug may be seized on some higher mileage vehicles, and not seating the bit may cause the bit to damage the plug. ^ Before removing the engine coolant temperature sensor, relieve any residual cooling system pressure by removing the radiator cap and then reinstalling it. Doing this will allow you to remove the sensor without having to drain the cooling system. ^ During assembly, DO NOT use any silicone products as they may cause damage to the oxygen sensors. ^ Allow the engine and cooling system to cool down prior to beginning this repair. Question -- Are these procedures the same as related procedures found in TSBs or in the Workshop Manual? Answer -- No. If you follow the procedures in this set of instructions, you will not need to disconnect the battery or install a memory saver, or drain and refill the cooling system. Also, this procedure involves removal of the upper and lower intake manifolds to replace the gaskets. Once the manifolds and the ECT are removed, the oil galley plug and the cam tensioner are easily accessed. LOWER INTAKE MANIFOLD REMOVAL 1. Remove the accelerator control splash shield. 2. Disconnect the speed control and accelerator cables from the throttle body control lever and the upper intake manifold. 3. Disconnect the intake air temperature (IAT) sensor. 4. Disconnect the fresh air tubes from the air cleaner outlet tube, then remove the air cleaner outlet tube. 5. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3242 6. Disconnect the following vacuum hoses: See Figures 1 and 2. ^ Brake booster. ^ Intake manifold tuning valve (IMTV) servo, if equipped. ^ Right side upper intake vacuum supply (two hoses). ^ PCV valve. 7. Remove the fasteners securing the EVR/VIS solenoid bracket. It is not necessary to disconnect the solenoids. Refer to Figure 2. 8. Remove the upper intake manifold screws. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3243 9. Lift up the upper intake manifold to access the vapor management valve (VMV) hoses. Remove the locking clips and disconnect the right and left VMV hoses. See Figure 3. 10. Remove the upper intake manifold by carefully sliding the manifold off of the exhaust gas recirculation (EGR) tube. See Figure 3. 11. If equipped, position the engine vacuum reservoir aside. See Figure 4. 12. Remove the lower intake manifold. See Figure 4. CAUTION: The intake ports of the cylinder heads must be covered to avoid any foreign material from entering the engine. 13. Clean all foreign material from the intake manifold/cylinder head area, then cover the cylinder head ports with clean shop towels. VOLUME REDUCTION PLUG AND CAM CHAIN TENSIONER REPLACEMENT Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3244 1. Disconnect the engine coolant temperature (ECT) sensor and the engine coolant temperature sender. Position the wiring harness connectors away from the oil galley plug area. See Figure 5. CAUTION: Damage to the oil galley plug will occur if the Torx(R) bit is not fully seated. Use a hand impact driver and an extension, striking the driver firmly, to loosen the plug. 2. Remove the oil galley plug. See Figure 5. 3. Install the volume reduction plug into the oil galley. See Figure 6. CAUTION: Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3245 The new oil galley plug comes pre-encapsulated with sealant. Do not apply additional sealant to the plug. 4. Install the new oil galley plug. Tighten the plug until it is flush with the face of the cylinder head. NOTE: Failure to remove then reinstall the radiator cap may result in coolant draining when the engine coolant temperature (ECT) sensor is removed. 5. Remove, then reinstall, the radiator cap. 6. Remove the ECT sensor only. See Figure 5. 7. Remove and discard the left cam chain tensioner and washer. See Figure 5. 8. Install the new cam chain tensioner and washer. Tighten the tensioner to 44 Nm (32 lb-ft). See Figure 7. 9. Install and connect the ECT sensor. Tighten the sensor to 15 Nm (132 lb-in). 10. Connect the coolant temperature sender. LOWER INTAKE MANIFOLD -- INSTALLATION 1. Remove the old gaskets from the lower intake manifold. Clean the manifold gasket mating surfaces. Remove the shop towels from the cylinder heads and clean the gasket mating surfaces. 2. Install new lower intake manifold gaskets, making sure they are correctly seated. 3. Install the lower intake manifold. Tighten the bolts to 18 Nm (13 lb-ft). 4. Install the engine vacuum reservoir, if equipped. 5. Install the locking clips onto the right and left VMV hose connectors. 6. Install the new upper intake manifold gaskets. CAUTION: When installing the upper intake manifold, be sure that all vacuum lines are positioned back to avoid pinching them under the manifold. CAUTION: DO Not use any silicone-based lubricants on the EGR tube 0-ring. NOTE: Using Penetrating and Lock Lubricant, E8AZ-19A501-B or equivalent non-silicone-based lubricant, lightly lubricate the EGR tube 0-ring to allow Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3246 for easier installation of the upper intake manifold. 7. Position the upper intake manifold carefully, slide the manifold onto the EGR tube and connect both right and left VMV hoses. Also, be sure to route the IAC valve connector into position. 8. Install the upper intake manifold screws. Tighten the screws to 7 Nm (62 lb-in). 9. Connect the IAC valve and TPS connector. 10. Install the EVR/VIS solenoid bracket. Tighten the screws to 3 Nm (26 lb-in). 11. Connect the following vacuum hoses: ^ Brake booster. ^ Intake manifold tuning valve (IMTV) servo, if equipped. ^ Right side upper intake vacuum supply (two hoses). ^ PCV valve. 12. Install the air cleaner outlet tube, and connect the fresh air tubes and IAT sensor. 13. Correctly route and secure the accelerator and speed control cables. Tighten the screws to 3 Nm (26 lb-in). 14. Install the accelerator control splash shield. 15. Start the engine and check for correct operation. Check and top off the cooling system as needed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3247 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3248 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3249 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket Technical Service Bulletin # 00M12 Date: 001101 Campaign - Camshaft Chain Tensioner & Intake Gasket 00M12 OWNER NOTIFICATION PROGRAM Certain 1997 through 2000 Explorer/Mountaineer and 2001 Explorer Sport/Sport-Trac Vehicles Equipped with 4.0L SOHC Engines - Camshaft Chain Tensioner and Lower Intake Manifold Gasket Additional Coverage ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Questions & Answer Sheet ^ Customer Notification Letter Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3255 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3256 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. NOTE: When a claim is submitted on an "M" program the VIN number will remain in OASIS until the terms of the program expire. CLAIMS PREPARATION AND SUBMISSION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3257 ^ Enter claims using DWE. ^ Refer to ACESII Manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company will only refund the cost of repairs for the camshaft chain tensioner and/or lower intake manifold gaskets 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). To qualify for the refund, the camshaft chain tensioner and/or lower intake manifold gasket must have been the causal part for the repair. All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII Manual for Refund information. Enter claims using DWE: Program Code: 00M12 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels as noted below: DOR/COR NUMBER DOR/COR for this program is 50196 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3258 DEALER PRICE For latest prices, check or call your: ^ 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. Attachment III - Technical Information OVERVIEW While performing this procedure the technician will install a: ^ New upper and lower intake manifold gaskets. ^ New cam chain tensioner and washer. ^ Volume reduction plug into the left cylinder head oil galley. ^ New oil galley plug. IMPORTANT TIME SAVING REPAIR TIPS ^ Always use a hand impact driver with a short extension when loosening the oil galley plug. Be sure the T-30 Torx(R) bit is in good condition, and that there is no foreign material inside the plug which would prevent the bit from fully seating. The plug may be seized on some higher mileage vehicles, and not seating the bit may cause the bit to damage the plug. ^ Before removing the engine coolant temperature sensor, relieve any residual cooling system pressure by removing the radiator cap and then reinstalling it. Doing this will allow you to remove the sensor without having to drain the cooling system. ^ During assembly, DO NOT use any silicone products as they may cause damage to the oxygen sensors. ^ Allow the engine and cooling system to cool down prior to beginning this repair. Question -- Are these procedures the same as related procedures found in TSBs or in the Workshop Manual? Answer -- No. If you follow the procedures in this set of instructions, you will not need to disconnect the battery or install a memory saver, or drain and refill the cooling system. Also, this procedure involves removal of the upper and lower intake manifolds to replace the gaskets. Once the manifolds and the ECT are removed, the oil galley plug and the cam tensioner are easily accessed. LOWER INTAKE MANIFOLD REMOVAL 1. Remove the accelerator control splash shield. 2. Disconnect the speed control and accelerator cables from the throttle body control lever and the upper intake manifold. 3. Disconnect the intake air temperature (IAT) sensor. 4. Disconnect the fresh air tubes from the air cleaner outlet tube, then remove the air cleaner outlet tube. 5. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3259 6. Disconnect the following vacuum hoses: See Figures 1 and 2. ^ Brake booster. ^ Intake manifold tuning valve (IMTV) servo, if equipped. ^ Right side upper intake vacuum supply (two hoses). ^ PCV valve. 7. Remove the fasteners securing the EVR/VIS solenoid bracket. It is not necessary to disconnect the solenoids. Refer to Figure 2. 8. Remove the upper intake manifold screws. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3260 9. Lift up the upper intake manifold to access the vapor management valve (VMV) hoses. Remove the locking clips and disconnect the right and left VMV hoses. See Figure 3. 10. Remove the upper intake manifold by carefully sliding the manifold off of the exhaust gas recirculation (EGR) tube. See Figure 3. 11. If equipped, position the engine vacuum reservoir aside. See Figure 4. 12. Remove the lower intake manifold. See Figure 4. CAUTION: The intake ports of the cylinder heads must be covered to avoid any foreign material from entering the engine. 13. Clean all foreign material from the intake manifold/cylinder head area, then cover the cylinder head ports with clean shop towels. VOLUME REDUCTION PLUG AND CAM CHAIN TENSIONER REPLACEMENT Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3261 1. Disconnect the engine coolant temperature (ECT) sensor and the engine coolant temperature sender. Position the wiring harness connectors away from the oil galley plug area. See Figure 5. CAUTION: Damage to the oil galley plug will occur if the Torx(R) bit is not fully seated. Use a hand impact driver and an extension, striking the driver firmly, to loosen the plug. 2. Remove the oil galley plug. See Figure 5. 3. Install the volume reduction plug into the oil galley. See Figure 6. CAUTION: Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3262 The new oil galley plug comes pre-encapsulated with sealant. Do not apply additional sealant to the plug. 4. Install the new oil galley plug. Tighten the plug until it is flush with the face of the cylinder head. NOTE: Failure to remove then reinstall the radiator cap may result in coolant draining when the engine coolant temperature (ECT) sensor is removed. 5. Remove, then reinstall, the radiator cap. 6. Remove the ECT sensor only. See Figure 5. 7. Remove and discard the left cam chain tensioner and washer. See Figure 5. 8. Install the new cam chain tensioner and washer. Tighten the tensioner to 44 Nm (32 lb-ft). See Figure 7. 9. Install and connect the ECT sensor. Tighten the sensor to 15 Nm (132 lb-in). 10. Connect the coolant temperature sender. LOWER INTAKE MANIFOLD -- INSTALLATION 1. Remove the old gaskets from the lower intake manifold. Clean the manifold gasket mating surfaces. Remove the shop towels from the cylinder heads and clean the gasket mating surfaces. 2. Install new lower intake manifold gaskets, making sure they are correctly seated. 3. Install the lower intake manifold. Tighten the bolts to 18 Nm (13 lb-ft). 4. Install the engine vacuum reservoir, if equipped. 5. Install the locking clips onto the right and left VMV hose connectors. 6. Install the new upper intake manifold gaskets. CAUTION: When installing the upper intake manifold, be sure that all vacuum lines are positioned back to avoid pinching them under the manifold. CAUTION: DO Not use any silicone-based lubricants on the EGR tube 0-ring. NOTE: Using Penetrating and Lock Lubricant, E8AZ-19A501-B or equivalent non-silicone-based lubricant, lightly lubricate the EGR tube 0-ring to allow Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3263 for easier installation of the upper intake manifold. 7. Position the upper intake manifold carefully, slide the manifold onto the EGR tube and connect both right and left VMV hoses. Also, be sure to route the IAC valve connector into position. 8. Install the upper intake manifold screws. Tighten the screws to 7 Nm (62 lb-in). 9. Connect the IAC valve and TPS connector. 10. Install the EVR/VIS solenoid bracket. Tighten the screws to 3 Nm (26 lb-in). 11. Connect the following vacuum hoses: ^ Brake booster. ^ Intake manifold tuning valve (IMTV) servo, if equipped. ^ Right side upper intake vacuum supply (two hoses). ^ PCV valve. 12. Install the air cleaner outlet tube, and connect the fresh air tubes and IAT sensor. 13. Correctly route and secure the accelerator and speed control cables. Tighten the screws to 3 Nm (26 lb-in). 14. Install the accelerator control splash shield. 15. Start the engine and check for correct operation. Check and top off the cooling system as needed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3264 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3265 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12 > Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3266 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Technical Service Bulletins > Page 3267 Timing Chain Tensioner: Specifications Jackshaft chain tensioner bolts 89 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > LH Timing Chain Tensioner: Service and Repair LH NOTE: Ford does not provide timing marks or additional information for servicing of the timing chains/sprockets without the special tools listed in this procedure. Timing Drive Components-LH Hydraulic Chain Tensioner Removal and Installation 1. Remove the upper intake manifold. 2. Remove the thermostat housing. 3. Remove the LH camshaft tensioner. - If using a new washer, tighten to 44Nm (32lb-ft). - If using the old washer, tighten to 67Nm (49 lb-ft). 4. Remove the pipe plug, and the oil volume reduction plug. 5. NOTE: Be sure to install the new oil volume reduction plug supplied with the hydraulic chain tensioner. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > LH > Page 3270 Timing Chain Tensioner: Service and Repair RH NOTE: Ford does not provide timing marks or additional information for servicing of the timing chains/sprockets without the special tools listed in this procedure. Removal and Installation 1. Remove the wheel and tire. 2. Remove the lower splash shield. 3. Remove the RH camshaft tensioner. - If using a new washer, tighten to 44 Nm (32 lb-ft). - If using the old washer, tighten to 67 Nm (49 lb-ft). 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Engine front cover bolts 14 ft.lb Jackshaft thrust plate bolts 8 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3274 Timing Cover: Service and Repair NOTE: Ford does not provide timing marks or additional information for servicing of the timing chains/sprockets without the special tools listed in this procedure. Removal 1. Drain the engine coolant. 2. Remove the crankshaft pulley. 3. Remove the accessory bracket and position aside. 4. Remove generator mounting bracket and position aside. 5. Disconnect the crankshaft position (CKP) sensor electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3275 6. Remove the water bypass hose. 7. Remove the lower heater water hose. 1 Squeeze the hose clamp. 2 Remove the hose. 8. Disconnect the lower radiator hose. 1 Squeeze the hose clamp. 2 Disconnect the hose. 9. On A/C equipped vehicles, remove the A/C line bracket and position aside. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3276 10. Remove the wiring harness retainer and position aside. 11. Note: The water pump is removed for clarity. Remove the engine front cover. Installation 1. Clean and inspect the sealing surfaces. 2. Install the engine front cover. 3. Install the wiring harness retainer. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3277 4. On A/C equipped vehicles, install the A/C line bracket nut. 5. Connect the lower radiator hose. 1 Position the hose 2 Install the clamp. 6. Connect the lower heater water hose. 1 Position the hose. 2 Install the hose clamp. 7. Install the water bypass hose. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3278 8. Connect the crankshaft position (CKP) sensor electrical connector. 9. Install the generator mounting bracket. 10. Install the accessory bracket. 11. Install the crankshaft pulley. 12. Raise and support the vehicle. 13. Drain the engine oil. 14. Lower the vehicle. 15. Fill the engine with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. 16. Fill the engine with coolant. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System Variable Valve Timing Actuator: Description and Operation Variable Cam Timing System Variable Cam Timing System Overview The Variable Cam Timing System allows the exhaust cam to advance and retard at varying engine speeds. The purpose of this is to reduce exhaust emissions and increase fuel economy. As the exhaust cam retards in relation to the crankshaft position, residual exhaust gases are left in the combustion chamber. The residual gases cool the combustion chamber and are inert when mixed with the incoming fresh charge of fuel and air. This results in better fuel economy and lower Nitrogen Oxides (NOx) and Hydrocarbons (HG) the engine produces. The Exhaust Gas Recalculation System (EGR) is unnecessary on the 2.0L (4V) engine due to this feature. Variable Cam Timing The Variable Cam Timing (VCT) system consists of the control solenoid, five-tooth pulse ring (4+1) on exhaust camshaft, Intake Air Temperature (IAT) sensor, Engine Coolant Temperature (ECT) sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor, Crankshaft Position (CKP) sensor, Powertrain Control Module (PCM) (Figure 129). 1. The Powertrain Control Module (PCM) receives input signals from the Intake Air Temperature (IAT) sensor, Engine Coolant Temperature (ECT) sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor and Crankshaft Position (CKP) sensor for determining the operating conditions of the engine. 2. The Variable Cam Timing (VCT) system is enabled by the PCM when the proper conditions are met. The PCM disables the VCT system if a fault is detected. 3. The PCM calculates relative cam position using the CMP sensor and data from the (4+1) pulse ring mounted on the exhaust camshaft. Relative cam position is calculated by measuring the time between the rising edge of Profile Ignition Pickup (PIP) and the falling edge of Variable Cam Timing (VCT) pulse. 4. The PCM continually calculates a cam position error value based on the difference between the desired and actual position and a duty cycle is commanded for the VCT solenoid valve. Engine oil is allowed to flow to the VCT unit. 5. Oil flows to either side of the piston chamber changing a linear motion from the piston to a rotation motion from the helical mechanism in the VCT unit. During closed loop the PCM outputs a revised duty cycle to the VCT solenoid valve to correct for cam position error. Variable Cam Timing System HARDWARE Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 3284 Variable Cam Timing (VCT) Solenoid Valve Variable Cam Timing (VCT) Solenoid Valve The VCT solenoid valve (Figure 130) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam timing. Variable Cam Timing Unit Assembly Variable Cam Timing (VCT) Unit Assembly The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the piston to move linearly along the axis of the camshaft. This linear motion is translated into rotational camshaft motion through the helical spline coupling. A spring installed Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 3285 in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up to 30 degrees. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 3286 Variable Valve Timing Actuator: Description and Operation Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing Unit Assembly The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the piston to move linearly along the axis of the camshaft. This linear motion is translated into rotational camshaft motion through the helical spline coupling. A spring installed in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up to 30 degrees. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Description and Operation Variable Valve Timing Solenoid: Description and Operation VARIABLE CAM TIMING (VCT) SOLENOID VALVE Variable Cam Timing (VCT) Solenoid Valve The Variable Cam Timing (VCT) solenoid valve (Figure 130) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam timing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Fuel Pressure Relief Valve Bolts 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information Fuel Pressure Test Port: Technician Safety Information WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information > Page 3297 Fuel Pressure Test Port: Vehicle Damage Warnings CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 3298 Fuel Pressure Test Port: Description and Operation PRESSURE TEST POINT There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE TEST KIT #134-ROO87 OR EQUIVALENT. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 3299 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Remove the upper intake manifold. For additional information, refer to Engine. 2. Disconnect fuel supply line. 3. Remove the four bolts and the fuel supply line from the fuel supply manifold. 4. Remove the fuel supply line bracket bolt and the fuel supply line. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. NOTE: Lubricate the new O-ring seals with Super Premium SAE 5W-30 Motor Oil, XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G, to aid installation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > With 104 Pin Processor Idle Speed: Specifications With 104 Pin Processor Hot Idle ................................................................................................................................................ ......................................................... 670 - 750 RPM Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > With 104 Pin Processor > Page 3304 Idle Speed: Specifications With 150 Pin Processor With Automatic Transmission Hot Idle ................................................................................................................................................ .................................................................. 750 RPM With Manual Transmission Hot Idle ................................................................................................................................................ .................................................................. 750 RPM Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Service and Repair Air Cleaner Housing: Service and Repair REMOVAL 1. Disconnect the air cleaner assembly. ^ Loosen the clamp and disconnect the outlet tube. ^ Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the air cleaner assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR 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. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3312 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL SERVICE TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR 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. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and attach the Fuel Pressure Gauge. 2. Open the manual valve on the Fuel Pressure Gauge slowly and relieve the fuel pressure. NOTE: Open the manual valve slowly to relieve the system pressure. This may drain fuel from the system. Place the fuel in a suitable container. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3313 Fuel Pressure Gauge Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Coil Terminal-To-Cylinder Relationship Firing order........................................................................................................................................... ..................................................................1-4-2-5-3-6 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 3317 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service Precautions Ignition Cable: Service Precautions CAUTION: ^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. ^ Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service Precautions > Page 3325 Ignition Cable: Service and Repair Spark Plug Wire Remover SPECIAL SERVICE TOOL(S) REMOVAL CAUTION: ^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. 1. With a twisting motion, use the special tool to pull the spark plug wire off the spark plug. 2. Squeeze the locking tabs and twist while pulling upward to remove the spark plug wires from the ignition coil. 3. Remove the spark plug wires. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service Precautions > Page 3326 1. To install, reverse the removal procedure. CAUTION: Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. NOTE: Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to the inside of the spark plug and ignition coil boots of the spark plug wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 1.3 - 1.4 mm RH Original Spark Plug AGRF22PG LH Original Spark Plug AGRF22P New Spark Plug (Either Side) AGSF22PP Spark Plugs 20 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 3331 Spark Plug: Specifications Spark Plug Gap 1.3 - 1.4 mm RH Original Spark Plug AGRF22PG LH Original Spark Plug AGRF22P New Spark Plug (Either Side) AGSF22PP Spark Plugs 20 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3332 Spark Plug: Application and ID RH Original Spark Plug Type .............................................................................................................. .............................................................. AGRF22PG LH Original Spark Plug Type ............................ .................................................................................................................................................... AGRF22P New Spark Plug Type (Either Side) ................................................................................... ................................................................................. AGSF22PP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3333 Spark Plug: Service and Repair REMOVAL 1. Remove the spark plug wires. For additional information, refer to Ignition Cable. 2. Remove the spark plugs. NOTE: ^ Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs. ^ If an original spark plug is reused, make sure it is installed in the same cylinder it was taken from. New spark plugs can be used in any cylinder. 3. Inspect the spark plugs. 4. Use a suitable spark plug gap tool to check and adjust the spark plug gap. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. For additional information, refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3337 Compression Check: Testing and Inspection 1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery is correctly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No.1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of Super Premium SAE 5W-30 Motor Oil, XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test-Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3338 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75 percent of the highest reading. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The 4.0L Push Rod engine has hydraulic lifters and requires no valve clearance adjustments. The 4.0L SOHC engine: - Manufacturer does not indicate whether the type of valve arrangement for this engine. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Water Pump Water Pump: Specifications Water pump bolts 6 - 9 ft.lb Water pump stud bolts 6 - 9 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Water Pump > Page 3346 Water Pump: Specifications Water pump pulley bolts 17 - 20 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3347 Water Pump: Service and Repair Removal 1. Remove the radiator. 2. Lift the accessory drive belt tensioner and remove the accessory drive belt. 3. Remove the belt idler pulley. 4. Slide the water bypass hose clamp back. 5. Disconnect the heater hose at the water pump. 1 Release the clamp. 2 Remove the hose. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3348 6. Disconnect the lower radiator hose at the water pump. 1 Release the clamp. 2 Remove the hose. 7. Remove the water pump pulley. 8. Remove the water pump. Installation 1. Note: Use Metal Surface Cleaner F4AZ-1DA536-RA or equivalent meeting Ford specification WSE-M5B392-A and a suitable plastic or wooden scraper to clean the scaling surfaces. Install the water pump. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3349 2. Connect the water bypass hose and position the clamp. 3. Install the water pump pulley. 4. Connect the lower radiator hose to the water pump. 1 Position the hose. 2 Install the clamp. 5. Connect the heater hose to the water pump. 1 Position the hose. 2 Install the clamp. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3350 6. Install the belt idler pulley. 7. Lift the accessory drive belt tensioner and install the drive belt. 8. Install the radiator. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Actuators and Solenoids - Cooling System > Hydraulic Cooling Fan Solenoid Valve > Component Information > Description and Operation Hydraulic Cooling Fan Solenoid Valve: Description and Operation HYDRAULIC COOLING FAN DRIVE Hydraulic Cooling Fan Pump With Integral Solenoid The system consists of an engine-driven pump with an integral solenoid (Figure 50) on the pump that is triggered by the powertrain control module (PCM). Fan speed is controlled by adjusting current to the solenoid, which then changes the fluid flow to the hydraulic motor. More current means the solenoid opens up, allowing higher pressure to increase the fan speed. The fan always turns due to solenoid current leakage, even in cold engine cases. The motor is driven by the pump. It contains a shaft on which the fan mounts. The motor also contains quick connect fittings for the high pressure lines. The cooler is similar to the power steering cooler (same purpose and function, to keep the fluid cool). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 3360 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity 16.3 qt (US) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 3363 Coolant: Fluid Type Specifications Antifreeze Type Ford Premium Engine Coolant (Green in color) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Drain Plug, Cylinder Block > Component Information > Specifications Coolant Drain Plug: Specifications Engine block coolant drain plug 12 - 18 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications Coolant Reservoir: Specifications Radiator Coolant Recovery Reservoir Bolts ....................................................................................................................................... 6-8 Nm (53-71 in.lb.) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications > Page 3370 Coolant Reservoir: Service and Repair Removal 1. Remove the air cleaner outlet tube and the engine air cleaner (ACL). 2. Remove the bolt and position the speed control servo aside. 3. Disconnect the windshield washer hose from under the dash panel and plug the end of the hose. 4. Disconnect the windshield washer pump electrical connector from the windshield washer reservoir. 5. Position the (A) clamp back and disconnect the (B) radiator overflow hose from the (C) radiator filler neck and plug the hose. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications > Page 3371 6. Remove the (A) two nuts and the (B) bolts. 7. Remove the radiator coolant recovery reservoir and the windshield washer reservoir. Installation 1. Install the radiator coolant recovery reservoir and the windshield washer reservoir. 2. Install the bolts and the two nuts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications > Page 3372 3. Connect the (B) radiator overflow hose to the (C) radiator filler neck and position the (A) clamp. 4. Connect the windshield washer pump electrical connector to the windshield washer reservoir. 5. Connect the windshield washer hose under the dash panel. 6. Position the speed control servo and bracket and install the bolt. 7. Fill the cooling system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair Fan Blade: Service and Repair Removal and Installation 1. Remove fan shroud. 2. Remove the bolts. 3. Separate the fan blade from the fan clutch. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Specifications Fan Clutch: Specifications Fan clutch to water pump pulley nut 34 - 36 ft.lb Fan blade to fan clutch bolts 14 - 19 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Specifications > Page 3380 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Hydraulic Cooling Fan Solenoid Valve > Component Information > Description and Operation Hydraulic Cooling Fan Solenoid Valve: Description and Operation HYDRAULIC COOLING FAN DRIVE Hydraulic Cooling Fan Pump With Integral Solenoid The system consists of an engine-driven pump with an integral solenoid (Figure 50) on the pump that is triggered by the powertrain control module (PCM). Fan speed is controlled by adjusting current to the solenoid, which then changes the fluid flow to the hydraulic motor. More current means the solenoid opens up, allowing higher pressure to increase the fan speed. The fan always turns due to solenoid current leakage, even in cold engine cases. The motor is driven by the pump. It contains a shaft on which the fan mounts. The motor also contains quick connect fittings for the high pressure lines. The cooler is similar to the power steering cooler (same purpose and function, to keep the fluid cool). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 15 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3388 Coolant Temperature Sensor/Switch (For Computer): Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3389 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3390 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Remove the thermostat and housing. For additional information, refer to Cooling System. 2. Disconnect the battery ground cable. For additional information, refer to Battery. 3. Remove the Engine Coolant Temperature (ECT) sensor. 1 Disconnect the connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor CYLINDER HEAD TEMPERATURE SENSOR Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy details. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor > Page 3395 Engine Temperature Sensor: Description and Operation Engine Coolant Temperature (ECT) Sensor ENGINE COOLANT TEMPERATURE (ECT) SENSOR Engine Coolant Temperature (ECT) Sensor The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Engine coolant temperature (ECT) sensor 89 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications > Page 3399 Temperature Sensor (Gauge): Description and Operation When the engine temperature is low, the resistance of the water temperature indicator sender unit is high, thus restricting the flow of current through the gauge and moving the pointer only a short distance. As the temperature of the coolant increases, the resistance decreases, allowing more current to flow through the gauge and results in a corresponding movement of the pointer. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Specifications Fan Shroud: Specifications Fan shroud bolts 53 - 71 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Specifications > Page 3403 Fan Shroud: Service and Repair Special Tools Removal and Installation 1. Remove the air cleaner outlet tube. 2. Use the Fan Clutch Wrench and the Fan Hub Wrench to loosen and remove the fan blade. 3. Remove the bolts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Specifications > Page 3404 4. Lift the fan shroud out of the lower retaining clips. 5. Lift the fan shroud and the fan blade and clutch assembly together and remove from the vehicle. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3413 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3414 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3420 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3421 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3422 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3423 Heater Core: Service Precautions WARNING: - CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3424 Heater Core: Description and Operation The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer it to air passing through the heater core. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3425 Heater Core: Testing and Inspection WARNING: CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. 1. Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good and did not require installation of a new heater core. If a heater core leak is suspected, the heater core must be tested by following the plugged heater core component test before the heater core pressure test. Carry out a system inspection by checking the heater system thoroughly. 2. Check the integrity of the heater water hose clamps. NOTE: Spring type clamps are installed as original equipment. Installation and overtightening of non-specification clamps can cause leakage at the heater water hose connection and damage the heater core. Heater Core-Plugged WARNING: THE HEATER CORE IN LET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. 1. Check to see that the engine coolant is at the correct level. 2. Start the engine and turn on the heater. 3. When the engine coolant reaches operating temperature, feel the heater core outlet hose to see if it is hot. If it is not hot. the heater core may have an air pocket - the heater core may be plugged - the thermostat is not working correctly. Heater Core-Pressure Test Use Radiator/Heater Core Pressure Tester to carry out the pressure test. 1. Drain the coolant from the cooling system. For additional information, refer to Cooling system. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water hose, approximately 101 mm (4 inches) long on each heater core tube. 4. Fill the heater core and heater water hoses with water and install Plug BT-7422-B and adapter BT-7422-A from the radiator/heater core pressure tester in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose clamps. 5. Attach the pump and gauge assembly from the Radiator/Heater Core Pressure Tester to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 241 kPa (35 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of three minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and carry out the bench test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3426 Heater Core-Bench Test 1. Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. 3. Connect the 101 mm (4 inch) test heater water hoses with plug and adapter to the core tubes. Then connect the radiator/heater core pressure tester to the adapter. 4. Apply 241 kPa (35 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, install a new heater core. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3427 Heater Core: Service and Repair Heater Core Removal and Installation Procedures Removal Note: If a heater core leak is suspected, the heater core must be leak tested before it is removed from the vehicle. 1. Drain the radiator. 2. Remove the heater water hose. 1. Squeeze the clamps and pull the hoses off. 2. Disconnect the vacuum hose from the water control valve. 3. Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 4. Remove the A/C evaporator core housing. 5. Remove the powertrain control module (PCM). 6. Remove the PCM heat sink. 1. Remove the ground strap screw. 2. Remove the heat sink. 7. Remove the heater air plenum nuts from the engine side of the dash panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3428 8. Remove the heater core. 1. Remove the heater core cover to air plenum screws. 2. Lift off the cover. 9. Remove the heater core. Installation Note: Be sure to install a new oval foam seal around the heater core inlet and outlet tubes. 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3437 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3438 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3444 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3445 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Page 3446 Heater Hose: Specifications Heater hose bracket bolts 27 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Page 3447 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Locations > Page 3452 Temperature Gauge: Testing and Inspection Magnetic Gauge Testing The Instrument Gauge System Tester is used to diagnose concerns with the instrument cluster magnetic gauges. To test the magnetic gauges: ^ Disconnect the connector from the appropriate sender and connect the signal wire to the Instrument Gauge System Tester. ^ Turn the vehicle ignition switch lock cylinder to the ON position. 1. Disconnect water temperature indicator sender unit C104. Connect one lead of Instrument Gauge System Tester to water temperature indicator sender unit C104, circuit 39 (RD/WH), and the other lead to ground. 2. Set Instrument Gauge System Tester to 300 ohms. Key ON. Wait one minute. The engine coolant temperature gauge should indicate C (cold). Key OFF. 3. Set Instrument Gauge System Tester to 45 ohms. Key ON. Wait one minute. The engine coolant temperature gauge pointer should be in the one quarter range to mid range. Key OFF. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Locations > Page 3453 4. Set Instrument Gauge System Tester to 18 ohms. Key ON. Wait one minute. The engine coolant temperature gauge should indicate H (hot). Key OFF. For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Instrument Cluster/Pinpoint Tests Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation Temperature Warning Lamp/Indicator: Description and Operation This warning message is displayed when the engine coolant is overheating. The message center indicator senses the voltage level on Circuit 39 (RD/WH) (to the message center indicator). If that voltage is greater than approximately 2.7 volts, at a battery voltage of 13.5 volts there will be no warning. If it is less than approximately 2.7 volts , at a battery voltage of 13.5 volts then the warning will be displayed. The message center indicator filters this input; therefore, there will be a few seconds delay before the warning is displayed or removed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Specifications Radiator Drain Plug: Specifications Radiator Draincock .............................................................................................................................. ....................................... 2.0-2.7 Nm (18-25 in. lbs.) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Specifications Radiator Cap: Specifications Pressure Test 13-18 psi Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 15 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 3469 Coolant Temperature Sensor/Switch (For Computer): Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 3470 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 3471 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Remove the thermostat and housing. For additional information, refer to Cooling System. 2. Disconnect the battery ground cable. For additional information, refer to Battery. 3. Remove the Engine Coolant Temperature (ECT) sensor. 1 Disconnect the connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor CYLINDER HEAD TEMPERATURE SENSOR Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy details. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor > Page 3476 Engine Temperature Sensor: Description and Operation Engine Coolant Temperature (ECT) Sensor ENGINE COOLANT TEMPERATURE (ECT) SENSOR Engine Coolant Temperature (ECT) Sensor The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Engine coolant temperature (ECT) sensor 89 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications > Page 3480 Temperature Sensor (Gauge): Description and Operation When the engine temperature is low, the resistance of the water temperature indicator sender unit is high, thus restricting the flow of current through the gauge and moving the pointer only a short distance. As the temperature of the coolant increases, the resistance decreases, allowing more current to flow through the gauge and results in a corresponding movement of the pointer. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Locations > Page 3484 Temperature Gauge: Testing and Inspection Magnetic Gauge Testing The Instrument Gauge System Tester is used to diagnose concerns with the instrument cluster magnetic gauges. To test the magnetic gauges: ^ Disconnect the connector from the appropriate sender and connect the signal wire to the Instrument Gauge System Tester. ^ Turn the vehicle ignition switch lock cylinder to the ON position. 1. Disconnect water temperature indicator sender unit C104. Connect one lead of Instrument Gauge System Tester to water temperature indicator sender unit C104, circuit 39 (RD/WH), and the other lead to ground. 2. Set Instrument Gauge System Tester to 300 ohms. Key ON. Wait one minute. The engine coolant temperature gauge should indicate C (cold). Key OFF. 3. Set Instrument Gauge System Tester to 45 ohms. Key ON. Wait one minute. The engine coolant temperature gauge pointer should be in the one quarter range to mid range. Key OFF. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Locations > Page 3485 4. Set Instrument Gauge System Tester to 18 ohms. Key ON. Wait one minute. The engine coolant temperature gauge should indicate H (hot). Key OFF. For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Instrument Cluster/Pinpoint Tests Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation Temperature Warning Lamp/Indicator: Description and Operation This warning message is displayed when the engine coolant is overheating. The message center indicator senses the voltage level on Circuit 39 (RD/WH) (to the message center indicator). If that voltage is greater than approximately 2.7 volts, at a battery voltage of 13.5 volts there will be no warning. If it is less than approximately 2.7 volts , at a battery voltage of 13.5 volts then the warning will be displayed. The message center indicator filters this input; therefore, there will be a few seconds delay before the warning is displayed or removed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Thermostat Opening Temperature Starts to open 183-190 F Fully open 210 F Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 3492 Thermostat: Description and Operation THERMOSTAT HEATER CONTROL Thermostat Assembly With Heater Control The primary objective for the thermostat heater control is for improvement in fuel economy and thermal efficiency. The system consists of a high temperature (98°C/208°F in lieu of a 90°C/194°F) thermostat (Figure 51)that has a resistive heater within the wax element. The heater is controlled by the PCM dependent on engine speed, throttle position, engine load, vehicle speed, air charge temperature, transmission oil temperature and engine coolant temperature. During low speed, low load and low air charge temperature conditions, the thermostat heater is OFF and the engine is allowed to operate at an elevated coolant temperature. This should result in lower internal friction and higher thermal efficiency, both leading to improved fuel economy. During high speed, high load, high temperature conditions (air charge, transmission oil or engine coolant), the PCM output is energized with a duty cycle to the thermostat heater. This heats the wax and forces the thermostat to rapidly open wider allowing extra coolant to flow from the radiator. This will reduce the coolant temperature and improve with performance demand. It should be noted that the heater is only capable of supplying a SMALL amount of additional heat to the wax element; it is NOT capable of opening the thermostat alone. The thermostat is 100% duty cycle for short calibrated time and than the duty cycle is reduce to a maximum of 70% on and 30% off. Approximately, unheated, the thermostat will begin to open at a coolant temperature of 98°C (208°F) and will be fully open at 115°C (239°F). Energizing the heater will reduce the opening temperature to about 80°C (176°F) and the fully open temperature to 110°C (230°F). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 3493 Thermostat: Service and Repair Removal and Installation 1. Partially drain the cooling system. 2. Remove the upper radiator hose. 3. Remove the bolts, water outlet adapter and thermostat. - Inspect the O-ring seal. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Water Pump Water Pump: Specifications Water pump bolts 6 - 9 ft.lb Water pump stud bolts 6 - 9 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Water Pump > Page 3498 Water Pump: Specifications Water pump pulley bolts 17 - 20 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 3499 Water Pump: Service and Repair Removal 1. Remove the radiator. 2. Lift the accessory drive belt tensioner and remove the accessory drive belt. 3. Remove the belt idler pulley. 4. Slide the water bypass hose clamp back. 5. Disconnect the heater hose at the water pump. 1 Release the clamp. 2 Remove the hose. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 3500 6. Disconnect the lower radiator hose at the water pump. 1 Release the clamp. 2 Remove the hose. 7. Remove the water pump pulley. 8. Remove the water pump. Installation 1. Note: Use Metal Surface Cleaner F4AZ-1DA536-RA or equivalent meeting Ford specification WSE-M5B392-A and a suitable plastic or wooden scraper to clean the scaling surfaces. Install the water pump. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 3501 2. Connect the water bypass hose and position the clamp. 3. Install the water pump pulley. 4. Connect the lower radiator hose to the water pump. 1 Position the hose. 2 Install the clamp. 5. Connect the heater hose to the water pump. 1 Position the hose. 2 Install the clamp. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 3502 6. Install the belt idler pulley. 7. Lift the accessory drive belt tensioner and install the drive belt. 8. Install the radiator. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3508 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3509 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3510 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3511 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3512 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3513 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3514 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3515 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3516 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3517 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3518 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3519 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3520 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3521 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3522 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3523 Catalytic Converter: Specifications Three-Way Catalytic Converter Bolts and Nut 25 - 34 ft.lb Three-Way Catalytic Converter-to-Exhaust Manifold Bolts (4.0L SOHC) 27 - 37 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions Catalytic Converter: Description and Operation Acronyms and Definitions 2V - L ACRONYMS AND DEFINITIONS NOTE: This Acronyms and Definitions listing contains technical terms applicable to Ford Motor Company products. It is not intended to be an all-inclusive dictionary of components and their functions. If a detailed description of a particular system or component is desired, refer to the applicable Vehicle System for the specific vehicle being serviced. 2V: Two Valve engine configuration. 4V: Four Valve engine configuration. ABS: Anti-lock Brake System. A/C: Air Conditioning. A vehicle accessory system that modifies the passenger compartment air by cooling and dehydrating the air. ACC: Air Conditioning Clutch. Indicates status of the A/C clutch. ACCS: Air Conditioning Cycling Switch. Indicates status of the A/C cycling switch. ACD: Air Conditioning Demand. A signal input to the PCM from the Air Conditioning control panel. ACP: Air Conditioning Head Pressure or A/C cycling switch input state. ACPSW: Air Conditioning Pressure Switch. ACPV: Air Conditioning Head Pressure Volts. A voltage input to the Powertrain Control Module (PCM) from the ACP switch or sensor. ACR: Air Conditioning Relay. Commanded output controlled by the PCM and acts as an A/C cutout control during heavy acceleration. A/D: Analog-to-Digital. Analog-to-Digital signal conversion. ADC: See ATDC. AFCM: Alternative Fuel Control Module. AIR: Secondary Air Injection. AIRB: Secondary Air Injection Bypass. Air Diverter: Air Diverter Valve. Part of the EAIR system. Diverts fresh air to the exhaust system when the electric air pump is commanded on. AIR EVAL: Air System Evaluated. Displays a YES or NO status indicating whether the Air System has been evaluated for OBD (On-Board Diagnostic) II purposes. Air/Fuel Ratio: Air to fuel mixture ratio. An air/fuel mixture that is 14.7:1 is also called stoichiometry. AIRM: Secondary AIR pump monitor. Ambient Air Temperature: Temperature of the air surrounding an object. Analog (Electrical/Electronic): An electrical signal that can obtain any value within the voltage limits of the signal. ARB: Air Resource Board. ARPMIDES: Ancillary RPM Desired. RPM required to maintain the vehicle speed commanded by Speed Control Command Switch (SCCS) inputs. ASCII: American Standard Code for Information Interchange. ATDC: After Top Dead Center. The location of the piston after it has reached the top of its stroke. Measured in degrees of crankshaft rotation. AVOM: Analog Volt-Ohm Multimeter. Readings are indicated by a sweep hand on a printed scale, rather than a digital display. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3526 AWD: All-Wheel Drive. BARO: Barometric Pressure. Base Idle: Idle rpm determined by the throttle lever hardset on the throttle body with the IAC solenoid disconnected. Base Timing: Spark advance in degrees before top dead center of the base engine without any control from the PCM or ICM. Battery Positive Voltage (B+): The positive (+) voltage from the battery or any circuit connected directly to the battery. Compare "Vehicle Power (VPWR)." BAT TEMP: Battery Temperature. BJB: Battery Junction Box. BOB: Breakout Box. A test device which connects in series to the PCM and PCM harness. BPA: Brake Pedal Applied switch. Typically located on the braking system master cylinder. Can be hydraulic or electric. BPP: Brake Pedal Position. Indicates the position of the brake pedal, based on input from the Brake Pedal Position (BPP) switch. BRAKE LMP or BRKL: Brake Warning Lamp Status. Activates the Brake Warning Lamp by applying voltage to the control line. BTDC: Before Top Dead Center. The location of the piston before it has reached the top of its stroke. Measured in degrees of crankshaft rotation. Bus + or Bus -: Multiplex circuits that carry Standard Corporate Protocol (SCP) data from module to module and to the DLC. CAC: Charge Air Cooler. Formerly known as Intercooler. A device which lowers the temperature of pressurized intake air. CAFE: Corporate Average Fuel Economy. A set of federal requirements and regulations which govern fuel economy standards. CANVNT: Canister Vent Solenoid. Catalyst: Catalytic converter. An in-line exhaust system device used to reduce the level of engine exhaust emissions. CAT EVAL: Catalyst System Evaluated. This item indicates YES when the Catalyst Efficiency Monitor has successfully completed. CCM: Comprehensive Component Monitor. CCRM: Constant Control Relay Module. A relay module that provides ON-OFF control of various EEC components. CD A through J: Coil Driver 1 through 10. Centralized Testing Facility: State government operation. Provides Inspection/Maintenance (IM) and safety inspections. CGND or CSE GND: Case Ground. Provides a ground source for the PCM or ECU case. CHT: Cylinder Head Temperature. Units are displayed in either degrees Fahrenheit or Centigrade. CHTIL: Cylinder Head Temperature Indicator Lamp. CHTV: Cylinder Head Temperature Voltage. The actual voltage drop across the CHT sensor thermistor. CID: Cylinder Identification. PCM input signal from Camshaft Position Sensor. CKP: Crankshaft Position. Senses the position of the crankshaft. CKP+, CKP-: CKP+ is the Crankshaft Position (CKP) sensor signal wire. CKP - is the signal return. CL: Closed Loop. An operating condition or mode which enables operation based on sensor feedback. CMP: Camshaft Position. Indicates camshaft position. CMPFM: Camshaft Position Failure Mode. Indicates when the PCM identifies a CID/CMP fault. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3527 CMS: Catalyst Monitor Sensor. Downstream H025. CMVSS: Canadian Motor Vehicle Safety Standards. CNG: Compressed Natural Gas. CO: Carbon Monoxide. A colorless, odorless and toxic gas that is a component of auto exhaust emissions. CO(2): Carbon Dioxide. A colorless, odorless gas that is a normal by-product of the combustion of fuel. Coil: A device consisting of windings around an iron core. In a spark ignition system, designed to increase voltage. Cold Soak: Time given to a vehicle to sit at a low temperature (typically below 68°F / 20°C) until the temperature of external and internal components stabilize. CONT: Continuous Memory. The portion of KAM (Keep Alive Memory) used to store DTCs generated during Continuous Memory Self-Test. Continuous Memory Self- Test: A continuous test of the EEC system conducted by the PCM whenever the vehicle is operating. CPP: Clutch Pedal Position. Indicates clutch pedal position. CPP Switch: Clutch Pedal Position Switch. Located on the clutch pedal and detects when the clutch pedal is depressed. CQIS: Common Quality Indicator System. CSE GND: Case Ground. CT: Closed Throttle Mode. A mode when the PCM varies the pulse width of the fuel injectors to obtain the air/fuel mixture appropriate for closed throttle operation. CTO: Clean Tach Output. Signal used to drive the instrument panel tachometer. Data Communications Link: A communication path between various in-vehicle electronic modules. Accessed by scan tools through the Data Link Connector (DLC). DC: 1. Direct Current. Electric current flowing in one direction. 2. Duty Cycle. The voltage measurement of ON time versus the full cycle period, expressed in percent. DCL: Data Communication Link. DI: Distributor Ignition. A system in which the ignition coil secondary circuit is sequenced by a distributor. Digital: Controls process information by switching the current or voltage ON and OFF. DLC: Data Link Connector. J1962 connector providing access to vehicle diagnostic information. DOHC: Dual Overhead Cam. An engine configuration that uses two camshafts positioned above the valves. DOL: Data Output Line. A circuit that sends certain information from the PCM to the instrument cluster. DPFEGR: Differential Pressure Feedback Exhaust Gas Recirculation. System that uses a pressure transducer to control the operation of the Exhaust Gas Recirculation (EGR) Vacuum Regulator Valve. DRI: Deposit Resistant Injector. A fuel injector designed to prevent build-up of carbon and other unwanted deposits. DRL: Daytime Running Lamps. A system that keeps the vehicle running lamps on at all times while the vehicle is operating. DTM: Diagnostic Test Mode. A level of capability in an On-Board Diagnostic (OBD) system. DTC: Diagnostic Trouble Code. An alpha/numeric identifier for a fault condition identified by the On-Board Diagnostic System. DVOM: Digital Volt-Ohm Meter. E-85: Fuel containing 85% ethanol alcohol. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3528 EAIR: Electric Secondary Air Injection. A pump-driven system for providing secondary air using an electric air pump. EAIRM: Electric Secondary Air Pump circuit Monitor. ECT: Engine Coolant Temperature. Displayed in either Fahrenheit or Centigrade. ECTV: Engine Coolant Temperature Voltage. The actual voltage drop across the ECT sensor thermistor. ECU: Electronic Control Unit. A module that handles the control strategy and monitors system inputs or outputs. EEC: Electronic Engine Control system. EEC-V: Fifth generation EEC system. EFT: Engine Fuel Temperature. EFTA: Bank 1 input. EFTA is displayed in either Fahrenheit or Centigrade. EFTAV: Voltage drop across the EFTA (Bank 1) sensor thermistor. EFTB: Bank 2 input. EFTB is displayed in either Fahrenheit or Centigrade. EFTBV: Voltage drop across the EFTB (Bank 2) sensor thermistor. EGR: Exhaust Gas Recirculation. A process in which a small amount of exhaust gas is routed into the combustion chamber. EGR EVAL: Exhaust Gas Recirculation System Evaluated. EGR EVAL will display YES when the monitor is complete. EGRMDSD: Electric Exhaust Gas Recirculation Motor Desired position. The PID name used to operate the Electric Exhaust Gas Recirculation (EEGR) valve with scan tool's output state control. EGRS: EGR Shutoff. A normally closed solenoid that applies vacuum to the EGR valve when energized by the PCM. EGRT: Exhaust Gas Recirculation Valve Temperature Sensor. A temperature sensor that is threaded into the bottom of the intake plenum. EGR Vacuum Regulator: Controls vacuum to the EGR valve by a duty cycle signal from the PCM. EGRVR: Exhaust Gas Recirculation Vacuum Regulator. Solenoid which varies the vacuum to the EGR valve by varying the duty cycle to the regulator. EGRVRA: Exhaust Gas Recirculation Vacuum Regulator Actual (volt). The actual state of the commanded output. EGRVRF: Exhaust Gas Recirculation Vacuum Regulator Fault. Represents whether a fault exists in the EGRV circuit. EI: Integrated Electronic Ignition. An Electronic Ignition system that has the Ignition Control Module (ICM) integrated into the PCM. EI-HDR: Electronic Ignition, High Data Rate. Formerly known as Electronic Distributorless Ignition System. EI-LDR: Electronic Ignition, Low Data Rate. Formerly known as Distributorless Ignition System. EMI: Electromagnetic Interference. Usually caused by ignition voltage spikes, solenoids, relay operation or noisy generator contacts. EOL: End Of Line. A system designed specifically for use at assembly plants to make sure all new vehicles perform to design specifications. EPA: Environmental Protection Agency (U.S. Government). EPROM: Erasable Programmable Read-Only Memory. An electronic component in the PCM that requires the electronic storage of information. ESOF: Electronic Shift-on-the-Fly. EVAP: Evaporative Emissions. A system to prevent fuel vapor from escaping into the atmosphere. EVAPCP: Evaporative Canister Purge Solenoid. Controls a solenoid which allows venting of the evaporative purge canister. EVAPCPF: Evaporative Canister Purge Solenoid Fault. Identifies whether an electrical fault exists for the current commanded state. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3529 EVAPCV: Evaporative Canister Vent Solenoid. Controls a solenoid which seals the EVAP system canister from atmospheric pressure during the EVAP OBD II Monitor test. Evaporative Emissions Canister: An evaporative emission canister, containing activated charcoal which absorbs and holds fuel vapors. EVAPPDC: Evaporative Canister Purge Duty Cycle. The duty cycle commanded to the Evap Canister Purge Solenoid by the PCM. EVO: Electronic Variable Orifice. EWP: Electric Water Pump. Exciter Ring: A toothed or notched iron or steel disk, which is the moveable part of a wheel speed sensor. FAN: Fan Speed. Used in conjunction with vehicles having multiple fan speed control. Displays OFF, LOW, or HIGH status. FC: Fan Control. FCS: Fuel Control Solenoid. FCIL: Fuel Cap Off Indicator Lamp. Indicates that the fuel filler cap was not properly installed. FEAD: Front End Accessory Drive. FEPS: Flash Electrically Erasable Programmable Read Only Memory (EEPROM) Programming Signal. 18 volt DC signal sent by the scan tool to initiate PCM reprogramming. FF: 1. Flexible Fuel. A system capable of using a variety of fuels for vehicle operation. 2. A PID that displays the % alcohol content in fuel. FFLRN: Flex Fuel Learned. Displays when the PCM's Flex Fuel strategy has completed calculating the inferred alcohol content of fuel. FFFM: Flexible Fuel Failure Mode. Indicates whether the current Flex Fuel Sensor reading (FF) is reliable or not. Displays a YES or NO. FFTEMP: Flexible Fuel Sensor - Temperature. Alcohol concentration derived from the signal pulse width. FFV: Flexible Fuel Vehicle. FIFO: First In First Out. FILO: First In Last Out. FIM: Fuel Indicator Module. FLI: Fuel Level Input. Used by the Evap monitor to calculate fuel tank vapor volume. Displayed as a percentage. FLIV: Fuel Level Input Voltage. FMEM: Failure Mode Effects Management. Operating strategy that maintains limited vehicle function in the event of a PCM or EEC component failure. FP:1. Fuel Pump. Indicates whether the pump has been commanded ON or OFF by the PCM. 2. Fuel Pump (Modulated). Fuel pump duty cycle percentage. FPDM: Fuel Pump Driver Module. A module that controls the electric fuel pump. FPF: Fuel Pump Fault. Identifies whether a fault exists in the FP circuit. FPM: Fuel Pump Monitor. Monitors the Fuel Pump I circuits for faults. Freeze Frame: A block of memory containing the vehicle operating conditions at a specific time. FRP: Fuel Rail Pressure. Based on FRP V. FRP V: Fuel Rail Pressure Voltage. A voltage input to the PCM from the Fuel Rail Pressure Sensor. FSC: Fail-Safe Cooling. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3530 FSV: Fuel Shut-off Valve. A component of Natural Gas Vehicles. This valve either allows or prevents Natural Gas flow to the fuel rail. FSVF: Fuel Shut-Off Valve Fault. Indicates if there is a fault in the FSV circuit. Displayed as YES or NO. FSVM: Fuel Shut-off Valve Monitor. Monitors operation of the Fuel Shut-Off Valve / circuit. FTP: Fuel Tank Pressure. Displayed as inches of water, kPa, or volts. FTP V: Fuel Tank Pressure Voltage. From the FTP transducer. FUEL PR: Fuel Pressure. Measurement of the force of the fuel delivered via the fuel pump. FUELPW: Fuel Pulse Width. Displays the commanded pulse width at time of last data update. FUELPW1: Fuel Injector Pulse Width #1. Corresponds to injectors normally affected by O2S1 (HEGO1). FUELPW2: Fuel Injector Pulse Width #2. Corresponds to injectors normally affected by O2S2 (HEGO2). FUELSYS: Fuel System Status (OPEN/CLOSED Loop). Formerly known as LOOP. Fuel Tank Vapor Valve: A valve mounted in the top of the fuel tank that vents excess vapor and pressure from the fuel tank into the Evaporative Emission Control System. FWD: Front Wheel Drive. GEM: Generic Electronic Module. GEN: Generator. GENF: Generator Output Fault. GENFDC: Generator Field Control Output. GFS: Generator field signal monitor. GND: Ground. GPM: Grams Per Mile. Also known as Gallons Per Minute. GPS: Global Positioning Satellite. Green State Vehicle: Formally known as California Emissions. A vehicle that is equipped with California on-board diagnostics. GSS: Gear Select Solenoid. GVW: Gross Vehicle Weight. Hall Effect: A process where current is passed through a small slice of semi-conductor material and a magnetic field to produce a small voltage in the semi-conductor. Hard Fault: A fault currently present in the system. HC: 1. Hydrocarbon. A by-product of combustion and a component of auto exhaust emissions. 2. High Compression. HCF: Hydraulic Cooling Fan. HCFD: Hydraulic Cooling Fan Drive. HFC: Hydraulic Cooling Fan. HFCF: High Fan Control Fault. Identifies if there is a fault in the HFC circuit. HFP: High Fuel Pump. HLOS: Hardware Limited Operating Strategy. A mode of operation where the PCM replaces output commands with fixed values in response to internal Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3531 PCM malfunctions. HO: High Output. HO2S: Heated Oxygen Sensor. Formerly known as Heated Exhaust Gas Oxygen (HEGO) Sensor. Provides information on rich or lean exhaust conditions to the PCM. Hot Soak: Period of time after an engine operates where localized combustion heat dissipates throughout the engine. HTR, HTR11, HTR12, HTR21 H1R22, HTRX1, HTRX2: HO2S Heater. Heater element for the HO2S sensor. Hydrogen: Chemical symbol H. Highly flammable gas. Hz: Hertz. Cycles per second. IAC: Idle Air Control. Electrical control of throttle bypass air. IAT: Intake Air Temperature. IATV: Intake Air Temperature Voltage. Actual voltage drop across the IAT sensor. IAT2: Intake Air Temperature 2. Displayed in either Fahrenheit or Centigrade. Used on supercharged vehicles. IAT2V: Intake Air Temperature 2 Voltage. Actual voltage drop across the IATV2 sensor. IC: Integrated Circuit. A small Semi-Conductor device capable of doing many separate circuit functions. ICM: Ignition Control Module. The module that controls the ignition system. IFDM: Integrated Fuel Delivery Module. IFS: Inertia Fuel Shutoff. IGN GND: Ignition Ground. Ignition: System used to provide high voltage spark for internal combustion engines. IGNKEY(IGKY): Ignition Key status. IGNSW (IGSW): Ignition Switch Position. IMRC: Intake Manifold Runner Control. Controls airflow through the high-speed runners in the intake manifold. IMRCM: Intake Manifold Runner Control Monitor. Monitors the IMRC / circuits for faults. IMTV: Intake Manifold Tuning Valve. Controls airflow through runners in a split intake manifold. INJ1, INJ2, INJ3, INJ4, INJ5, INJ6, INJ7, INJ8, INJ9, INJ1O: lnjector number or its signal output from the PCM. Injector: A device for delivering metered pressurized fuel to the intake system or the cylinders. Intake Air: Air drawn through a filter and distributed to each cylinder for use in combustion. Intercooler: See CAC. IPATS: Integrated Passive Anti-Theft System. ISO: international Standards Organization. KAM: Keep Alive Memory. A portion of the memory within the PCM that must have power even when the vehicle is not operating. KAPWR: Keep Alive Power. Dedicated, unswitched power circuit that maintains KAM. Key On Engine Off Self- Test: A test of the EEC system conducted by the PCM with power applied and the engine at rest. Key On Engine Running Self- Test: A test of the EEC system conducted by the PCM with the engine running and the vehicle at rest. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3532 KEYPWR: Key Power. Battery voltage supplied when the ignition key is in the ON position. Knock: The sharp metallic sound produced when two combustion pressure fronts collide in the combustion chamber of an engine. KOEC: Key On Engine Continuous. KOEO: Key On Engine off. KOER: Key On Engine Running. KPA: Kilopascal. Unit of pressure. 3.386 kPa = 1 inch of mercury (Hg.). KPH: Kilometers Per Hour. KS: Knock Sensor. Detects engine knock. L: Liters. The unit of volume in the metric measuring system. One liter equals 1.06 quarts. LEV: Low Emissions Vehicle. LFC: Low Fan Control. LFP: Low Fuel Pump. Reduced operating speed for multi-speed fuel pumps. LIFO: Last In First Out. LILO: Last In Last Out. LONGFT1, LONGFT2: Long-Term Fuel Trim. Fuel flow adjustment determined by the PCM. LOOP: indicates OPEN or CLOSED loop status. LPG: Liquefied Petroleum Gas. LPLR: Low Pressure Low Resistance fuel injector. M-V ACRONYMS AND DEFINITIONS NOTE: This Acronyms and Definitions listing contains technical terms applicable to Ford Motor Company products. It is not intended to be an all-inclusive dictionary of components and their functions. If a detailed description of a particular system or component is desired, refer to the applicable Vehicle System for the specific vehicle being serviced. M-85: Fuel containing 85% methanol alcohol. MAF: Mass Air Flow. Used to measure the mass (weight) of the air entering the engine. MAF RTN: Mass Air Flow Return. A return circuit for the MAF sensor. MAP: Manifold Absolute Pressure. The internal pressure of the intake manifold. MFC: Medium Fan Control. MFI: Multiport Fuel Injection. A fuel-delivery system in which each cylinder is individually fueled. MFP: Modulated Fuel Pump. Microprocessor: A digital processor on a chip which perform arithmetic and control logic. MIL: Malfunction Indicator Lamp. An indicator lamp alerting the driver of an emission related malfunction. May also read "CHECK ENGINE" or "SERVICE ENGINE SOON." MISF: Misfire. Any event in the cylinder that causes a sudden change in acceleration of the crankshaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3533 MON: Motor Octane Number. Monolithic Substrate: The ceramic honeycomb structure used in the catalytic converter. MSOF: Manual Shift-on-the-Fly. MY: Model Year. NA: Naturally Aspirated. Engine that is not supercharged or turbocharged. NAAO: North American Automotive Operations. NC: Normally Closed. NG: Natural Gas. A system capable of using natural gas for vehicle operation. NGS: New Generation STAR (Self-Test Automatic Readout) tester. NGVM: Natural Gas Vehicle Module. NO: Norm ally Open. NO(x): Oxides of Nitrogen. Formed at high combustion temperatures. NVH: Noise, Vibration, Harshness. A classification of vehicle concerns. OASIS: On-Line Automotive Service Information System. OBD, OBD-II: On-Board Diagnostics, On-Board Diagnostics Second Generation. A system that monitors PCM input and output control signals. On Demand Test: Technician initiated "KOEO" and "KOER" tests performed by the PCM. OC: Oxidation Catalytic converter. A catalytic converter system that reduces levels of HC and CO. OCT ADJ: Octane Adjust. Compensating strategy that adjusts for changes in fuel octane. OEM: Original Equipment Manufacturer. OHC: OverHead Cam. An engine configuration that uses a single camshaft positioned above the valves. OWL: Overheat Warning Lamp or its signal output from the PCM. Turns the TEMP warning lamp ON when engine oil temperature exceeds safe limits. Open Circuit: A circuit which does not provide a complete path for flow of current. OL: Open Loop. An operating condition based on instructions not modified by PCM feedback. O(2)S 11/12/21/22: Oxygen Sensor and its relative position in the exhaust system. Detects oxygen content in exhaust gasses. OSC: Output State Control. OSS: Output Shaft Speed. Ozone: A blue gaseous form of oxygen (O(3)) formed naturally by electric discharge or exposure to ultraviolet radiation. Particulate: Small solid matter found in exhaust gases, especially prevalent in diesel engines. PATS: Passive Anti-Theft System. PATSIL: Passive Anti-Theft System Indicator Light. PATSIN: Passive Anti-Theft System Receive Signal. PATSOUT: Passive Anti-Theft System Transmit Signal. PATSTRT: Passive Anti-Theft System Starter Relay Control Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3534 PCM: Powertrain Control Module. Formerly known as the EEC (Electronic Engine Control) Processor. PCV: Positive Crankcase Ventilation. A system which allows the controlled flow of crankcase vapors into the combustion chamber. PF: Purge Flow. Amount of fuel vapor burned in the engine. Photochemical: Term describing the action of light on air pollutants which results in creating smog. PID: Parameter Identifier. Identifies an address in PCM memory which contains operating information. Powertrain: Engine and transmission/transaxle components. Pressure - Absolute: A pressure referenced to a perfect vacuum. Pressure - Atmospheric: The pressure of the surrounding air at any given temperature and altitude. Sometimes called Barometric Pressure. Pressure - Barometric: Pertaining to atmospheric pressure or the results obtained by a barometer. Pressure - Differential: The pressure difference between two regions, such as between the intake manifold and atmospheric pressure. Pressure - Gage: The amount by which absolute pressure exceeds the ambient atmospheric pressure. PIP: Profile Ignition Pickup. Provides crankshaft position information for ignition synchronization. Potentiometer: An adjustable resistance component commonly used as a sensor (Example: TP Sensor). PPM: Parts Per Million. A measure used in emission analysis. PROM: Programmable Read-Only Memory. Similar to ROM except without program instructions. Protocol: A set of rules for the exchange of information on a network. PSOM: Programmable Speedometer/Odometer Module. A module that processes vehicle speed information. PSP: Power Steering Pressure. Indicates the pressure in the power steering system. PSP V: Power Steering Pressure Input Voltage. PTEC: Powertrain Electronic Controller. PTO: Power Take-Off. PW: Pulse Width. The length of time an actuator, such as a fuel injector, remains energized. PWM: Pulse Width Modulation. Controls the intensity of an output by varying the signal duty cycle. PWR GND: Power Ground. The main ground circuit in the EEC system. Quick Test: A series of diagnostic tests of the EEC system consisting of KOEO, KOER and Continuous Memory Self-Tests. Results are displayed as a series of DTCs. RABS: Rear Antilock Brake System. RAM: Random Access Memory. Memory into which information can be written as well as read. REDOX: Reduction Oxidation Catalytic converter. A catalytic converter system designed to operate at high temperatures. Regulator: Controls the alternator/generator field current to maintain proper battery charge. Contained within the PCM in smart charging applications. Relay: An electromechanical device in which connections in one circuit are opened or closed by changes in another circuit. REM: Rear Electronic Module. Repetitive Spark: Multiple firings of individual spark plugs at engine speeds below 1000 RPM to improve idle quality and improve emissions. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3535 RF: Radio Frequency. RFI: Radio Frequency Interference. RFS: Returnless Fuel System. RM: Relay Module. A module containing two or more relays. ROM: Read-Only Memory. Computer memory that can be accessed and utilized, but not altered. RON: Research Octane Number. Routine: A group of related tasks, such as a series of diagnostic tests. RPM: Revolutions Per Minute. RS: Reverse Switch. RTN: Return. A dedicated sensor ground circuit. RWD: Rear Wheel Drive. SAE: Society of Automotive Engineers. SBS: Supercharger Bypass Solenoid or its signal output from the PCM. SC: Supercharged or Supercharger. SCB: Supercharger Bypass Control. A system that allows manifold vacuum to be bled away from the supercharger wastegate actuator to allow for maximum boost. SCBF: Supercharger Bypass Control Fault. Identifies whether a fault exists in the Supercharger Bypass circuit. SCICP: Supercharger Intercooler Pump Control. SCICPF: Supercharger Intercooler Pump Control Fault. SCIPC: The PID to monitor the operation of the Supercharger and Charge Air Cooler pump. SCP: Standard Corporate Protocol. Self- Test: See Quick Test. Sensor: A device that detects the value or change in a physical quantity, such as temperature, pressure or flow rate, and converts the data into an electrical signal. SFI: Sequential Multi port Fuel Injection. A multiport fuel delivery system where each injector is individually energized and timed relative to its cylinder intake event. Shield: A conducting sleeve that surrounds wires to be electronically isolated from Electromagnetic Interference (EMI). Short Circuit: An undesirable condition in a circuit where it is terminated at a point other than that intended. SHRT FT: Short-Term Fuel Trim. Fuel flow adjustment in response to the HO2S sensor(s) input during closed-loop operation. SIG RTN: Signal Return. A dedicated sensor ground circuit that is common to two or more sensors. SIL: Shift Indicator Lamp. Smart Driver: A PCM or ECU output driver that can detect faults (open or shorts) on its output circuit. SME: Society of Manufacturing Engineers. SOF: Shift-On-the-Fly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3536 SOHC: Single Overhead Cam. Solenoid: A device consisting of an electrical coil which produces a magnetic field in a plunger and pulled to a central position. ST: Scan Tool. A device that interfaces with and communicates information on a data link. Stoichiometry: An air/fuel mixture that is neither too rich nor too lean. Stoichiometric ratio is 14.7 parts of air for every 1 part of fuel. Switch: A device for making, breaking, or changing the connections in an electrical circuit. TA: Traction Assist. TACH: Tachometer. TB: Throttle Body. A device that controls airflow through the engine via a butterfly valve, and has an air bypass channel around the throttle plate. TC: 1. Traction Control. Combines anti-lock braking and axle torque reduction to control wheel slippage. 2. Turbocharger. TDC: Top Dead Center. Tear Tag: The two-piece adhesive label attached to the PCM to identify its calibration. Thermistor: A temperature dependent resistor, like that used in CHT and ECT sensors. Timing: Relationship between spark plug firing and piston position expressed in crankshaft degrees before (BTDC) or after (ATDC) top dead center of the compression stroke. TMAP: Thermal Manifold Absolute Pressure Sensor. A MAP Sensor that includes a thermistor to measure intake air temperature. TP: Throttle Position (sensor). A three-wire potentiometer that provides throttle angle and rate information for the PCM. TP V: Throttle Position Sensor Voltage. Transducer: A device that receives energy from one medium and transfers it to another. For example, thermal energy is converted to an electrical signal through a temperature probe. Transmissions/Transaxles: NOTE: All related items are grouped under the general heading "TRANSMISSIONS" located at the end. TSB: Technical Service Bulletin. Notifies service personnel of any known vehicle concerns, procedures, or general service information. Underspeed Mode: A control mode that prevents the engine from stalling in the event it stumbles while running. Also used during engine crank. Vacuum: Manifold pressure that is reduced below the ambient atmospheric pressure. Variable Reluctance: A process of passing a varying magnetic field through wire windings and inducing a voltage. VCT: Variable Camshaft Timing. VECI: Vehicle Emission Control Information label. VIN: Vehicle Identification Number. A unique identification number given to every vehicle produced. Includes information about the year, model, engine, and plant origin of the vehicle. VMV: Vapor Management Valve. Controls the flow of fuel vapors out of the carbon canister. VOM: Volt-Ohm Meter. Readings are indicated by sweep hand on a printed scale rather than a digital (DVOM) display. VPWR: Vehicle Power. A switched circuit that provides power to the EEC system. Compare "Battery Voltage VREF: Reference Voltage. A dedicated circuit that provides approximately a 5.0 volt signal used as a reference by certain sensors. WAC: Wide Open Throttle A/C Cut-off. Turns A/C system off during wide open throttle or certain other operating conditions. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3537 Wastegate Control: A device that opens the wastegate in case of overboost from a turbocharger. WOT: Wide Open Throttle. A condition of maximum airflow through the throttle body. Zip Tube: Another name for "fresh air duct" or "air inlet duct". TRANSMISSIONS: NOTE: The transmission naming convention is as follows: ^ The first character, a number, is the number of forward gears. ^ The second character, either the letter "F" or "R," represents front (transaxle) or rear (transmission) wheel drive. ^ The next set of characters, a grouping of numbers, represents the design torque capacity of the transmission/transaxle (for example, "27" represents 270ft./lbs. in the 4F27E transaxle). ^ The last character, if used, is one of the following: ^ "E" for electronic shift ^ "N" for non-synchronous shift ^ "S" for synchronous shift ^ "W" for wide ratio ^ 4F27E: Also known as the FN Focus automatic transmission. ^ 4F44E: Formerly known as the CD4E. ^ 4F46S: Formerly known as the Ax45 and regular-duty AXOD-E. ^ 4F50N: Formerly known as the Ax4N and heavy-duty AXOD-E. ^ 4R44E: Formerly known as A4LD for 3.0L applications. ^ 4R55E: Formerly known as A4LD for 4.0L applications. ^ 4R70W: Formerly known as AOD-E. ^ 4R100: Formerly known as E4OD. ^ 5R44E: Formerly known as A5LD for 3.0L applications. ^ 5R55E: Formerly known as A5LD for 4.0L applications. ^ 5R55N: Lincoln LS automatic transmission. ^ 5R55W: Wide-ratio truck transmission. ^ 4x4L: 4x4 Low. ^ A/T: Automatic Transmission. ^ CCS: Coast Clutch Solenoid. ^ CCSF: Coast Clutch Solenoid Fault. Displays a YES if fault exists. ^ EPC: Electronic Pressure Control. ^ EPCV: Electronic Pressure Control Volts. ^ ESS: Electronic Shift Scheduling. ^ HCDSS: High Clutch Drum Speed Sensor. PCM input from the 4R44E and 4R55E. ^ M5OD: Manual 5-Speed transmission with overdrive (RWD). ^ M/T: Manual Transmission/Transaxle. ^ NPS: Neutral Pressure Switch or its signal input to the PCM. ^ OCS: Overdrive Cancel Switch. ^ OSS: Output Shaft Speed. Indicates rotational speed of the transmission output shaft. ^ PNP: Park/Neutral Position switch. Also known as Neutral Drive Switch (NDS), Neutral Gear Switch (NGS), and Transmission Switch Neutral (TSN). ^ REVERSE or REV: Transmission Reverse Switch Input. ^ SIL: Shift Indicator Lamp. A lamp that indicates the preferred shift points on select manual transmission/transaxle vehicles. ^ S91/SS2/SS3: Shift solenoids. Devices that control the shifting in an automatic transmission. ^ TCC: Torque Converter Clutch. When energized, causes a mechanical engagement and disengagement of the Torque Converter Clutch. ^ TCIL: Transmission Control Indicator Lamp. Indicates that the Transmission Control Switch (TCS) has been activated. ^ TCS: Transmission Control Switch. Modifies the operation of electronically controlled transmissions. ^ Torque converter: A device which by its design multiplies the torque in a fluid coupling between an engine and transmission/transaxle. ^ TFT: Transmission Fluid Temperature. Indicates temperature of transmission fluid. ^ Transaxle: A device consisting of a transmission and axle drive gears assembled in the same case. Front-wheel drive applications. ^ Transmission: A device which selectively increases or decreases the ratio of relative rotation between its input and output shafts. Rear-wheel drive applications. ^ TR: Transmission Range. The range in which the transmission is operating. ^ TR Sensor: Formerly known as Manual Lever Position Sensor (MLPS). Provides information to the PCM on the transmission range selector position. ^ TR V: Transmission Range Voltage. ^ TSS: Turbine Shaft Speed. Indicates rotational speed of the transmission turbine shaft. ^ VSS: Vehicle Speed Sensor. A magnetic pickup device that generates an AC signal that is proportional to vehicle speed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3538 Catalytic Converter: Description and Operation Catalyst Efficiency Monitor - Federal Test Procedure Catalyst Efficiency Monitor - Federal Test Procedure The Catalyst Efficiency Monitor uses an oxygen sensor before and after the catalyst to infer the hydrocarbon efficiency based on oxygen storage capacity of the catalyst. Under normal, close-loop fuel conditions, high efficiency catalysts have significant oxygen storage. This makes the switching frequency of the rear Heated Oxygen Sensor (HO2S) very slow and reduces the amplitude of those switches as compared to the switching frequency and amplitude of the front HO2S. As the catalyst efficiency deteriorates, its ability to store oxygen declines. The post-catalyst or downstream HO2S signal begins to switch more rapidly with increasing amplitude, approaching the switching frequency and amplitude of the pre-catalyst or upstream HO2S. All applications utilize an FTP-based (Federal Test Procedure) catalyst monitor. This simply means that the catalyst monitor must run during a standard FTP emission test as opposed to the 20-second steady state catalyst monitor used in 1994 through some 1996 vehicles. Two slightly different versions of the catalyst monitor are used in the 2001 model year. Switch Ratio Method (1996 - 2001) 1. In order to assess catalyst oxygen storage, the monitor counts front and rear HO2S switches during part-throttle, close-loop fuel condition after the engine is warmed-up and inferred catalyst temperature is within limits. Front switches are accumulated in up to nine different air mass regions or cells although three air mass regions is typical. Rear switches are counted in a single cell for all air mass regions. When the required number of front switches has accumulated in each cell, the total number of rear switches is divided by the total number of front switches to compute a switch ratio. A switch ratio near 0.0 indicates high oxygen storage capacity, hence high HC efficiency. A switch ratio near 1.0 indicates low oxygen storage capacity, hence low HC efficiency. If the actual switch ratio exceeds a calibrated threshold switch ratio, the catalyst is considered failed. Inputs from Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CHT) (warm engine), IAT (not extreme ambient temperatures), Mass Air Flow (MAF) (greater than minimum engine load), Vehicle Speed Sensor (VSS) (within vehicle speed widow) and Throttle Position (TP) (at part-throttle) are required to enable the Catalyst Efficiency Monitor. 2. The DTCs associated with this test are Diagnostic Trouble Code (DTC) P0420 (Bank 1) and P0430 (Bank 2). Because an Exponentially Weight Moving Average algorithm is use for malfunction determination, up to six driving cycles may be required to illuminate the Malfunction Indicator Lamp (MIL) during normal customer driving. If Keep Alive Memory (KAM) is reset, a malfunction will illuminate the MIL in 2 drive cycles. Index Ratio Method (some 2001 and beyond) 1. In order to assess catalyst oxygen storage, the catalyst monitor counts front HO2S switches during part-throttle, closed-loop fuel conditions after the engine is warmed-up and inferred catalyst temperature is within limits. Front switches are accumulated in up to three different air mass regions or cells. While catalyst monitoring entry conditions are being met, the front and rear HO2S signal lengths are continually being calculated. When the required number of front switches has accumulated in each cell, the total signal length of the rear HO2S is divided by the total signal length of the front HO2S to compute a catalyst index ratio. An index ratio near 0.0 indicates high oxygen storage capacity, hence high efficiency. A switch ratio near 1.0 indicates low oxygen storage capacity, hence low HC efficiency. If the actual index ratio exceeds the threshold index ratio, the catalyst is considered failed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3539 Inputs from ECT or CHT (warm engine), IAT (not extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed widow) and TP (at part-throttle) are required to enable the Catalyst Efficiency Monitor. 2. The DTCs associated with this test are DTC P0420 (Bank 1) and P0430 (Bank 2). Because an Exponentially Weighted Moving Average algorithm is use for malfunction determination, up to six driving cycles may be required to illuminate the MIL during normal customer driving. If KAM is reset, a malfunction will illuminate the MIL in 2 drive cycles. If the catalyst monitor does not complete during a particular driving cycle, the already accumulated switch/signal data is retained in Keep Alive Memory and is used during the next driving cycle to allow the catalyst monitor a better opportunity to complete. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3540 Catalytic Converter: Description and Operation Catalyst and Exhaust Systems Catalyst and Exhaust System Overview The Catalytic Converter and Exhaust Systems (Figure 135) work together to control the release of harmful engine exhaust emissions into the atmosphere. The engine exhaust gas consists mainly of Nitrogen (N), Carbon Dioxide (CO2) and Water Vapor (H2O). However, it also contains Carbon Monoxide (CO), Oxides Of Nitrogen (NOx), Hydrogen (H), and various unburned Hydrocarbons (HCs). CO, NO(x), and HCs are major air pollutants, and their emission into the atmosphere must be controlled. The exhaust system generally consists of an exhaust manifold, front exhaust pipe, upstream Heated Oxygen Sensor (HO2S), rear exhaust pipe, downstream HO2S, a muffler and an exhaust tailpipe. The catalytic converter is installed between the front and rear exhaust pipes. Catalytic converter efficiency is monitored by the On Board Diagnostic (OBD II) system. Generic Catalyst and Exhaust System Catalytic Converter A catalyst is a material that remains unchanged when it initiates and increases the speed of a chemical reaction. A catalyst will also enable a chemical reaction to occur at a lower temperature. The concentration of exhaust gas products released to the atmosphere must be controlled. The catalytic converter assists in this task. It contains a catalyst in the form of a specially treated honeycomb structure saturated with catalytically active precious metals. As the exhaust gases come in contact with the catalyst, they are changed into mostly harmless products. The catalyst initiates and speeds up heat producing chemical reactions of the exhaust gas components so they are used up as much as possible. Exhaust System The purpose of the exhaust system is to convey engine emissions from the exhaust manifold to the atmosphere. Engine exhaust emissions are directed from the engine exhaust manifold to the catalytic converter through the front exhaust pipe. An HO2S is mounted on the front exhaust pipe before the catalyst. The catalytic converter reduces the concentration of Carbon Monoxide (CO), unburned Hydrocarbons (HCs) and Oxides of Nitrogen (NO) in the exhaust emissions to an acceptable level. The reduced exhaust emissions are directed from the catalytic converter to a muffler through the rear exhaust pipe. Another HO2S is mounted on the rear exhaust pipe. Lastly, the exhaust emissions are directed to the atmosphere through an exhaust tailpipe. HARDWARE The downstream HO2S may be located after the light off catalyst or underbody catalyst. The underbody catalyst may be in-line with the light off catalyst, or the underbody catalyst may be common to two light off catalysts, forming a "Y" pipe configuration. For an exact configuration of the catalyst and exhaust system, refer to Exhaust System. Three Way Catalytic Converter The Three Way Catalytic (TWC) converter contains either platinum (Pt) and Rhodium (Rh) or Palladium (Pd) and Rhodium (Rh). The TWC converter catalyzes the oxidation reactions of unburned HCs and CO and the reduction reaction of NO. The three-way conversion can be best accomplished by always operating the engine air fuel/ratio at or close to stoichiometry. Exhaust Manifold/Runners The exhaust manifold runners collect exhaust gases from engine cylinders. The number of exhaust manifolds and exhaust manifold runners depends on the engine configuration and number of cylinders. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 3541 Exhaust Pipes Exhaust pipes are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The pipes serve as guides for the flow of exhaust gases from the engine exhaust manifold through the catalytic converter and the muffler. Upstream Heated and Downstream Heated Oxygen Sensors The HO2S provide the Powertrain Control Module (PCM) with voltage and frequency information related to the oxygen content of the exhaust gas. In addition to providing the PCM with indications of how rich/lean the engine is operating, the upstream HO2S signal serves as an input to the HO2S monitor. The downstream HO2S signal is an input to the Catalyst Efficiency monitor. Muffler Mufflers are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The muffler reduces the level of noise produced by the engine, and it also reduces the noise produced by exhaust gases as they travel from the catalytic converter to the atmosphere. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 3542 Catalytic Converter: Testing and Inspection For information regarding diagnosis of this system refer to Computers and Control Systems Diagnosis. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 3543 Catalytic Converter: Service and Repair Removal 1. Remove the muffler assembly. 2. Disconnect the heated oxygen sensor (HO2S) connectors. 3. Remove the bolts. 4. Remove the bolts and nuts. 5. Remove the LH three way catalytic converter (TWC). 6. Remove the bolts. 7. Twist and remove the RH TWC. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 3544 Installation 1. Note: Before installing the TWCs, install new gaskets. Follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust manifold nuts 16 ft.lb Exhaust manifold to exhaust pipe bolts 30 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > LH Exhaust Manifold: Service and Repair LH Removal and Installation 1. Raise and support the vehicle. 2. Remove the bolts. 3. Lower the vehicle. 4. Disconnect the hoses from the differential pressure feedback (EGR) transducer. 5. Disconnect the EGR valve to exhaust manifold tube from the exhaust manifold. 6. Disconnect the EGR valve to exhaust manifold tube from the EGR valve and remove the EGR valve to exhaust manifold tube. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > LH > Page 3550 7. Remove the LH exhaust manifold. 8. Note: Use new exhaust manifold gaskets and nuts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > LH > Page 3551 Exhaust Manifold: Service and Repair RH Removal 1. Raise and support the vehicle. 2. Remove the bolts. 3. Lower the vehicle. 4. Remove the RH exhaust manifold. 5. Note: Use new exhaust manifold gaskets and nuts. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair Heat Shield: Service and Repair 1. Disconnect the battery cable. 2. Raise the vehicle. 3. Inspect the catalytic converter and muffler for loose or missing heat shields. 4. Install worm clamps for heat shields that are loose. - Use one of the following clamps: FOTZ-5A231-A or W705949-S300. - Trim off the excess ear of the worm clamp. 5. If the heat shields are missing, install new heat shields. If new heat shields are not available, install a new catalytic converter. 6. Lower the vehicle. 7. Reconnect the battery cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications Muffler: Specifications Muffler to Three-Way Catalytic Converter Bolts 22 - 36 ft.lb Muffler to TWC Clamp Bolt 44 - 58 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications > Page 3558 Muffler: Service and Repair Removal 1. Remove the two bolts and loosen the clamp. 2. Disconnect the RH torsion bar link. - Remove the nut and position the torsion bar link out of the way. 3. Pry the rear support slide out of the rubber insulator. 4. Pry the double support slides away from the insulators. 5. Remove the muffler. Slide the muffler forward over the rear axle while twisting the muffler until the muffler is removed. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications > Page 3559 1. Install the muffler over the rear axle and twist the muffler into position. 2. Note: Before installing the muffler into the rubber insulators, apply a soap solution to the support slides. Push the double support slides into the rubber insulators. 3. Push the rear support slide into the rubber insulator. 4. Position the RH torsion bar and install the nut. 5. Install the bolts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications > Page 3560 6. Tighten the clamp. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures Powertrain Control Module: Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3568 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3569 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Technical Service Bulletins > Page 3570 Powertrain Control Module: Specifications PCM Connector 5 - 7 Nm Powertrain Control Module Connector Bolt 7 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Technical Service Bulletins > Page 3571 Powertrain Control Module: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Technical Service Bulletins > Page 3572 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Technical Service Bulletins > Page 3573 Powertrain Control Module: Diagrams Part (1 Of 3) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Technical Service Bulletins > Page 3574 Part (2 Of 3) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Technical Service Bulletins > Page 3575 Part (3 Of 3) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Description and Operation > General Description and Operation Powertrain Control Module: Description and Operation General Description and Operation The PCM performs the following functions: ^ accepts input from various engine sensors to compute the required fuel flow rate necessary to maintain a prescribed air/fuel ratio throughout the entire engine operational range. ^ outputs a command to the fuel injectors to meter the appropriate quantity of fuel. ^ determines and compensates for the age of the vehicle and its uniqueness, also automatically senses and compensates for changes in altitude. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Description and Operation > General Description and Operation > Page 3578 Powertrain Control Module: Description and Operation Standard Models (Non BI-Fuel) POWERTRAIN CONTROL MODULE - VEHICLE SPEED OUTPUT (VSO) The PCM-VSO (Powertrain Control Module - Vehicle Speed Output) speed signal subsystem generates vehicle speed information for distribution to the vehicle's electrical/electronic modules and subsystems that require vehicle speed data. This subsystem senses the transmission output shaft speed with a sensor. The data is processed by the PCM, and distributed as a hard-wired signal or as a multiplexed data message. The key features of the PCM-VSO system are to: ^ Infer vehicle movement from the output shaft sensor signal ^ Convert transmission output shaft rotational information to vehicle speed information ^ Compensate for tire size and axle ratio with a programmed calibration variable ^ Utilize a transfer case sensor for four wheel drive applications ^ Distribute vehicle speed information as a multiplexed message and/or an analog signal The signal from a non-contact shaft sensor (Output Shaft Sensor--OSS or Transfer Case Shaft Sensor--TCSS) mounted on the transmission (automatics, manuals, or 4X4 transfer cases) is sensed directly by the PCM. The PCM converts the OSS or TCSS information to 8000 pulses per mile, based on a tire and axle ratio conversion factor. This conversion factor is programmed into the PCM at the time the vehicle is assembled and can be reprogrammed in the field for servicing changes in the tire size and axle ratio. The PCM transmits the computed vehicle speed and distance traveled information to all the vehicle speed signal users on the vehicle. VSO information can be transmitted by a hard-wired interface between the vehicle speed signal user and the PCM, or by Speed and Odometer SCP multiplexed data messages. The VSO hard-wired signal wave form is a DC square wave with a voltage level of 0 to VBAT. Typical output operating range is 2.22Hz per MPH (1.3808 Hz pr 1 Km/h). Multiplexed data for speed and distance data are transmitted as separate SCP messages over the SCP multiplex link. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Flash Electrically Eraseable Programmable Read Only Memory Powertrain Control Module: Service and Repair Flash Electrically Eraseable Programmable Read Only Memory Flash Electrically Eraseable Programmable Read Only Memory - Flash EEPROM Description Flash Electrically Eraseable Programmable Read Only Memory (EEPROM) is contained in an Integrated Circuit (IC) internal to the Powertrain Control Module (PCM). The EEPROM contains the vehicle strategy including calibration information specific to the vehicle and is capable of being reprogrammed or reflashed repeatedly. As part of the calibration there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM as under Programming the VID Block for a Replacement PCM. Failure to perform this procedure may generate fault code: P1639, VID Block not programmed or is corrupt. The VID block in an existing Powertrain Control Module (PCM). can also be tailored to accommodate various hardware changes made to the vehicle since production. Failure to perform this procedure properly may generate fault code: P1635, Tire/Axle Ratio out of Acceptable Range. This is described under Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the VIN number, octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control and four wheel drive electronic shift on the fly versus manual shift on the fly. Only items applicable to vehicle hardware and supported by the VID block will be displayed on the scan tool. When changing items in the VID block, the strategy will place range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool will display a message indicating the need to flash the PCM again to reset the VID block. Each of the procedures described below use the Worldwide Diagnostic System (WDS). Reprogramming can be performed by a local Ford dealer for any non Ford facility. There are other Enhanced Scan Tools that may have reprogramming capabilities available. Refer to the diagnostic tool manufacturers users manual for details. Programming the VID Block for a Replacement PCM A new PCM will contain the latest strategy and calibration level for a particular vehicle. However, the VID block will be blank and will need programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM and the second is manual data entry into the new PCM. Automatic data transfer will be performed if the old PCM is capable of communicating. This is done by the use of a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can now be downloaded to the new PCM after it has been replaced. Manual data entry must be performed if the old module is damaged and is incapable of communicating. Remove and replace the old PCM. You may be instructed to contact the "AS BUILT" data center for the information needed to manually update the VID block with the scan tool. Contact the center ONLY if the old PCM cannot be used or the data is corrupt. For Ford L-M technician's, contact your National Hotline for "AS Built" data. Non Ford technicians, use the Fed World website at "fedworld.gov". Select Auto Service Information and search for "Calibrations" or "Vehicle Calibrations" then specify vehicle manufacturer, model name and model year as required. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate vehicle hardware. Refer to PCM/Module Reprogramming on the Scan Tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM will need to be completely reprogrammed. This is due to changes made to the strategy or calibration after production or the need to reset the VID block because it has reached its limit. Refer to PCM/Module Reprogramming on the Scan Tool. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Flash Electrically Eraseable Programmable Read Only Memory > Page 3581 Powertrain Control Module: Service and Repair Removal and Installation REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Powertrain Control Module (PCM) electrical connector. 3. Remove the nuts and the PCM cover. 4. Remove the PCM. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3585 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3586 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Emission Control Systems > Air Injection Pump Relay > Component Information > Description and Operation Air Injection Pump Relay: Description and Operation SOLID STATE RELAY Solid State Relay The solid state relay (Figure 124) switches the high current required for operation of the electric AIR pump. Input control to the solid state relay comes from the Powertrain Control Module (PCM). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3595 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3596 Fuel Pump Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3600 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3601 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Description and Operation Absolute Pressure Sensor: Description and Operation THERMAL MANIFOLD ABSOLUTE PRESSURE SENSOR Thermal Manifold Absolute Pressure (TMAP) Sensor The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 41) consists of a Manifold Absolute Pressure (MAP) sensor and an integrated thermistor. The thermistor part of the sensor is currently not being used. The MAP part of the sensor measures intake manifold air absolute pressure. The PCM uses information from the MAP sensor, Throttle Position (TP) sensor, Mass Air Flow (MAF) sensor, Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CKP) sensor and Crankshaft Position (CKP) sensor to determine how much exhaust gas is introduced into the intake manifold. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications Mass Air Flow Sensor: Specifications Mass Air Flow Sensor Nuts And Bolts 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3610 Mass Air Flow Sensor: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3611 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3612 Mass Air Flow Sensor: Description and Operation MASS AIR FLOW SENSOR Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3613 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Loosen the air cleaner outlet tube clamp and position aside. 4. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor, Stud Bolt 19 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3617 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3618 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3619 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the CMP sensor electrical connector. 2 Remove the CMP sensor stud bolt. 3 Remove the camshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams > Page 3623 Clutch Switch: Description and Operation CLUTCH PEDAL POSITION SWITCH Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch (Figure 24) is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference Vehicle Reference Voltage (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 15 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 3627 Coolant Temperature Sensor/Switch (For Computer): Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 3628 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 3629 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Remove the thermostat and housing. For additional information, refer to Cooling System. 2. Disconnect the battery ground cable. For additional information, refer to Battery. 3. Remove the Engine Coolant Temperature (ECT) sensor. 1 Disconnect the connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolts 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3633 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Electronic Engine Controls Crankshaft Position Sensor: Description and Operation Electronic Engine Controls The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Electronic Engine Controls > Page 3636 Crankshaft Position Sensor: Description and Operation Standard Models (Non BI-Fuel) CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference (Figure 25). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Page 3637 Crankshaft Position Sensor: Service and Repair REMOVAL NOTE: The 5.0L is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Crankshaft Position (CKP) sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ 4.0L SOHC and 4.0L (push rod) CKP sensors need to be touching the damper. The CKP sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure sensor wiring is routed away from the battery cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor CYLINDER HEAD TEMPERATURE SENSOR Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy details. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor > Page 3642 Engine Temperature Sensor: Description and Operation Engine Coolant Temperature (ECT) Sensor ENGINE COOLANT TEMPERATURE (ECT) SENSOR Engine Coolant Temperature (ECT) Sensor The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation The fuel sending unit is a variable resistor made up of a ceramic substrate. It is controlled by the action of a float arm. When the fuel level is low, resistance in the unit is low. When the fuel level is high, the resistance is high. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3649 Fuel Tank Pressure Sensor: Service Precautions CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3650 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The Fuel Tank Pressure (FTP) sensor (Figure 97) or inline Fuel Tank Pressure (FTP) sensor (Figure 98) is used to measure the fuel tank pressure during the EVAP monitor test on vehicles equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank pressure by forcing the system to purge. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3651 Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Remove the fuel tank. For additional information, refer to Fuel Delivery and Air Induction. 2. Remove the fuel tank pressure sensor. 1 Disconnect the electrical connector. 2 Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the fuel tank. CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. INSTALLATION 1. To install, reverse removal procedure. ^ Leak test the evaporative emission system. For additional information, refer to Evaporative Emission System Leak Test System. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emissions repair verification drive cycle. For additional information, refer to Evaporative Emission Repair Verification Drive Cycle. See: Emission Control Systems/Evaporative Emissions System/Service and Repair Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation Intake Air Temperature Sensor: Description and Operation INTAKE AIR TEMPERATURE SENSOR Intake Air Temperature (IAT) Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire Terminals The Intake Air Temperature (IAT) sensors (Figure 34) and integrated Mass Air Flow (MAF) type (Figure 37), are thermistor devices in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Page 3655 Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel spark and MAF. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Supercharged 5.4L Lightning vehicles use (2) AT sensors. Both sensors operate as above. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor Second Intake Air Temperature (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Bolt 25 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 3659 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 3660 Knock Sensor: Description and Operation Knock Sensor Two Types Of Knock Sensor (KS) The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 3661 Knock Sensor: Service and Repair REMOVAL 1. Remove the lower in take manifold. For additional information, refer to Engine. 2. Remove the knock sensor. 1 Remove the bolt. 2 Remove the knock sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3666 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3667 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3668 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3669 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3670 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3671 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3672 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3673 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3674 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3675 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3676 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3677 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3678 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3679 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3680 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Page 3681 Heated Oxygen Sensor: Specifications Heated Oxygen Sensor 41 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations > Oxygen Sensor Bank Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations > Oxygen Sensor Bank Locations > Page 3684 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated Oxygen 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3687 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3688 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3689 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3690 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3691 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3692 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3693 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3694 Heated Oxygen Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3695 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3696 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3697 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3698 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3699 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3700 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3701 Heated Oxygen Sensor: Connector Views Ford does not provide connector views for this vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 3702 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Heated Oxygen Sensor (HO2S) Monitor Heated Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S) Monitor Heated Oxygen Sensor Monitor The Heated Oxygen Sensor (HO2S) Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration which can affect emissions. The fuel control or upstream HO2S is checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S used for Catalyst Monitor are also monitored for proper output voltage. The following illustration shows that input is required from the Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CHT), Intake Air Temperature (IAT), Mass Air Flow (MAF) and Crankshaft Position (CKP) sensors to activate the HO2S Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. 1. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. The HO2S Monitor evaluates both the upstream (fuel control) and downstream (Catalyst Monitor) HO2S for proper function. 2. Once the HO2S Monitor is enabled, the upstream HO2S signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. A HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the Output State Monitor (OSM) and by measuring the current going through the heater circuit. The HO2S Monitor DTCs can be categorized as follows: The Diagnostic Trouble Code (DTCs) associated with HO2S lack of switching are DTCs P1130, P1131, P1132, P1150, P1151 and P1152. The DTCs associated with HO2S slow response rate are DTCs P0133 and P0153. The DTCs associated with HO2S signal circuit malfunction are DTCs P0131, P0136, P0148, P0151 and P0156. The DTCs associated with a HO2S heater circuit malfunction are DTCs P0135, P0141, P0155 and P0161. The Diagnostic Trouble Code (DTC) associated with the downstream HO2S not running in on-demand is DTC P1127. The DTCs associated with swapped HO2S connectors are DTCs P1128 and P1129. 3. The Malfunction Indicator Lamp (MIL) is activated after a fault is detected on two consecutive drive cycles. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Heated Oxygen Sensor (HO2S) Monitor > Page 3705 Heated Oxygen Sensor: Description and Operation PCM Inputs HEATED OXYGEN SENSOR Heated Oxygen Sensor (HO2S) The Heated Oxygen Sensor (HO2S) (Figure 33) detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop operation. The Vehicle Power (VPWR) circuit supplies voltage to the heater and the PCM will complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater and heater control system are installed on some vehicles. The high power heater reaches closed loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 3706 Heated Oxygen Sensor: Service and Repair EGO Sensor Wrench SPECIAL SERVICE TOOL(S) REMOVAL NOTE: The 5.0L RH is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar. 1. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 2. Remove the bolts and the skid plate. 3. Remove the Three Way Catalytic Converter (TWC). For additional information, refer to Catalytic Converter. 4. Using the special tool, remove the HO2S. NOTE: If necessary, lubricate the HO2S with Penetrating and Lock Lubricant E8AZ-19A501-B or equivalent to assist in removal. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply a light coat of High Temperature Nickel Anti-Sieze Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A to the threads of the HO2S. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 3707 Syncro Positioning Tool Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of 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). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3716 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3717 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3718 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3719 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3720 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of 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). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3726 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3727 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3728 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3729 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3730 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3735 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3736 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3737 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3743 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3744 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3745 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 3746 Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR Bolts 8 - 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 3747 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 3748 Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 3749 Tube Mounted Differential Pressure Feedback EGR Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 3750 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the differential pressure feedback EGR electrical connector. 3. Disconnect the differential pressure feedback EGR hoses. 4. Remove the bolts and the differential pressure feedback EGR. INSTALLATION 1. Fit the differential pressure feedback EGR and loosely install the bolts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 3751 2. Tighten the bolts. 3. Connect the differential pressure feedback EGR hoses. 4. Connect the differential pressure feedback EGR electrical connector. 5. Connect the battery ground cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3755 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs Throttle Position Sensor: Description and Operation PCM Inputs THROTTLE POSITION SENSOR Typical Throttle Position (TP) Sensor The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs > Page 3758 Throttle Position Sensor: Description and Operation Intake Air Systems THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the On-Board Diagnostic (OBD) II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page 3759 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the accelerator control snow shield. 3. Remove the Throttle Position (TP) sensor. 1 Disconnect the TP sensor electrical connector. 2 Remove the sensor. NOTE: The 4.0L (SOHC) is shown, the 4.0L push rod is similar. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital transmission range (TR) sensor screws 71 - 97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3763 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3764 Digital Transmission Range Sensor: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3765 Digital Transmission Range Sensor: Service and Repair Special Tools Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the shift cable. 1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the bracket. 4. Disconnect the digital transmission range (TR) sensor electrical connector. 5. Remove the manual control outer lever nut and manual control outer lever. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3766 6. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor. 1. Position the digital TR sensor. 2. Loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Note: The manual lever must he in the neutral position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever. 1. Install the manual control outer lever. 2. Install the manual control outer lever nut. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3767 4. Connect the digital transmission range (TR) sensor electrical connector. 5. Connect the shift cable. 1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. Connect the battery ground cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Vehicle Speed Sensor Bolt 98 - 115 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3773 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3774 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3775 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3776 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3777 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3778 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3779 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3780 Vehicle Speed Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3781 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3782 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3783 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3784 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3785 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3786 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3787 Diagram 64-1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 3788 Vehicle Speed Sensor: Description and Operation VEHICLE SPEED SENSOR Typical Vehicle Speed Sensor (VSS) The Vehicle Speed Sensor (VSS) (Figure 45) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling and torque converter clutch scheduling. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of 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). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3798 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3799 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3800 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3801 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3802 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of 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). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3808 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3809 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3810 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3811 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3812 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3817 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3818 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3819 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 3825 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 3826 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 3827 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 3828 Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR Bolts 8 - 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 3829 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 3830 Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 3831 Tube Mounted Differential Pressure Feedback EGR Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 3832 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the differential pressure feedback EGR electrical connector. 3. Disconnect the differential pressure feedback EGR hoses. 4. Remove the bolts and the differential pressure feedback EGR. INSTALLATION 1. Fit the differential pressure feedback EGR and loosely install the bolts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 3833 2. Tighten the bolts. 3. Connect the differential pressure feedback EGR hoses. 4. Connect the differential pressure feedback EGR electrical connector. 5. Connect the battery ground cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications Mass Air Flow Sensor: Specifications Mass Air Flow Sensor Nuts And Bolts 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3838 Mass Air Flow Sensor: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3839 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3840 Mass Air Flow Sensor: Description and Operation MASS AIR FLOW SENSOR Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3841 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Loosen the air cleaner outlet tube clamp and position aside. 4. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation Fuel Pressure Sensor/Switch: Description and Operation FUEL RAIL PRESSURE SENSOR Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor (Figure 31) is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor (Figure 32) senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3848 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch (Figure 72) is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner Guide for the location of the IFS. Inertia Fuel Shutoff (IFS) Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3849 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Disconnect the battery. For additional information, refer to Battery. 2. Access the Inertia Fuel Shutoff (IFS) switch on the RH toe board and disconnect the electrical connector. 3. Remove the bolts and remove the IFS switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3853 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs Throttle Position Sensor: Description and Operation PCM Inputs THROTTLE POSITION SENSOR Typical Throttle Position (TP) Sensor The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs > Page 3856 Throttle Position Sensor: Description and Operation Intake Air Systems THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the On-Board Diagnostic (OBD) II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 3857 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the accelerator control snow shield. 3. Remove the Throttle Position (TP) sensor. 1 Disconnect the TP sensor electrical connector. 2 Remove the sensor. NOTE: The 4.0L (SOHC) is shown, the 4.0L push rod is similar. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor, Stud Bolt 19 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3862 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3863 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3864 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the CMP sensor electrical connector. 2 Remove the CMP sensor stud bolt. 3 Remove the camshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolts 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3868 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Electronic Engine Controls Crankshaft Position Sensor: Description and Operation Electronic Engine Controls The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Electronic Engine Controls > Page 3871 Crankshaft Position Sensor: Description and Operation Standard Models (Non BI-Fuel) CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference (Figure 25). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Page 3872 Crankshaft Position Sensor: Service and Repair REMOVAL NOTE: The 5.0L is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Crankshaft Position (CKP) sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ 4.0L SOHC and 4.0L (push rod) CKP sensors need to be touching the damper. The CKP sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure sensor wiring is routed away from the battery cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. 2. Prove out the air bag system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 3878 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 3879 4. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. Installation WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 3880 WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Note: Use a new ignition switch lock cylinder. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. 2. Prove out the air bag system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Bolt 25 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 3884 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 3885 Knock Sensor: Description and Operation Knock Sensor Two Types Of Knock Sensor (KS) The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 3886 Knock Sensor: Service and Repair REMOVAL 1. Remove the lower in take manifold. For additional information, refer to Engine. 2. Remove the knock sensor. 1 Remove the bolt. 2 Remove the knock sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Fuel Pressure Relief Valve Bolts 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information Fuel Pressure Test Port: Technician Safety Information WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information > Page 3894 Fuel Pressure Test Port: Vehicle Damage Warnings CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 3895 Fuel Pressure Test Port: Description and Operation PRESSURE TEST POINT There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE TEST KIT #134-ROO87 OR EQUIVALENT. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 3896 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Remove the upper intake manifold. For additional information, refer to Engine. 2. Disconnect fuel supply line. 3. Remove the four bolts and the fuel supply line from the fuel supply manifold. 4. Remove the fuel supply line bracket bolt and the fuel supply line. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. NOTE: Lubricate the new O-ring seals with Super Premium SAE 5W-30 Motor Oil, XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G, to aid installation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > With 104 Pin Processor Idle Speed: Specifications With 104 Pin Processor Hot Idle ................................................................................................................................................ ......................................................... 670 - 750 RPM Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > With 104 Pin Processor > Page 3901 Idle Speed: Specifications With 150 Pin Processor With Automatic Transmission Hot Idle ................................................................................................................................................ .................................................................. 750 RPM With Manual Transmission Hot Idle ................................................................................................................................................ .................................................................. 750 RPM Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Service and Repair Air Cleaner Housing: Service and Repair REMOVAL 1. Disconnect the air cleaner assembly. ^ Loosen the clamp and disconnect the outlet tube. ^ Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the air cleaner assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR 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. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3909 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL SERVICE TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR 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. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and attach the Fuel Pressure Gauge. 2. Open the manual valve on the Fuel Pressure Gauge slowly and relieve the fuel pressure. NOTE: Open the manual valve slowly to relieve the system pressure. This may drain fuel from the system. Place the fuel in a suitable container. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3910 Fuel Pressure Gauge Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Coil Terminal-To-Cylinder Relationship Firing order........................................................................................................................................... ..................................................................1-4-2-5-3-6 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 3914 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service Precautions Ignition Cable: Service Precautions CAUTION: ^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. ^ Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service Precautions > Page 3922 Ignition Cable: Service and Repair Spark Plug Wire Remover SPECIAL SERVICE TOOL(S) REMOVAL CAUTION: ^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. 1. With a twisting motion, use the special tool to pull the spark plug wire off the spark plug. 2. Squeeze the locking tabs and twist while pulling upward to remove the spark plug wires from the ignition coil. 3. Remove the spark plug wires. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service Precautions > Page 3923 1. To install, reverse the removal procedure. CAUTION: Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. NOTE: Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to the inside of the spark plug and ignition coil boots of the spark plug wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 1.3 - 1.4 mm RH Original Spark Plug AGRF22PG LH Original Spark Plug AGRF22P New Spark Plug (Either Side) AGSF22PP Spark Plugs 20 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 3928 Spark Plug: Specifications Spark Plug Gap 1.3 - 1.4 mm RH Original Spark Plug AGRF22PG LH Original Spark Plug AGRF22P New Spark Plug (Either Side) AGSF22PP Spark Plugs 20 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3929 Spark Plug: Application and ID RH Original Spark Plug Type .............................................................................................................. .............................................................. AGRF22PG LH Original Spark Plug Type ............................ .................................................................................................................................................... AGRF22P New Spark Plug Type (Either Side) ................................................................................... ................................................................................. AGSF22PP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3930 Spark Plug: Service and Repair REMOVAL 1. Remove the spark plug wires. For additional information, refer to Ignition Cable. 2. Remove the spark plugs. NOTE: ^ Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs. ^ If an original spark plug is reused, make sure it is installed in the same cylinder it was taken from. New spark plugs can be used in any cylinder. 3. Inspect the spark plugs. 4. Use a suitable spark plug gap tool to check and adjust the spark plug gap. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. For additional information, refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3934 Compression Check: Testing and Inspection 1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery is correctly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No.1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of Super Premium SAE 5W-30 Motor Oil, XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test-Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3935 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75 percent of the highest reading. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The 4.0L Push Rod engine has hydraulic lifters and requires no valve clearance adjustments. The 4.0L SOHC engine: - Manufacturer does not indicate whether the type of valve arrangement for this engine. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor > Component Information > Description and Operation Absolute Pressure Sensor: Description and Operation THERMAL MANIFOLD ABSOLUTE PRESSURE SENSOR Thermal Manifold Absolute Pressure (TMAP) Sensor The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 41) consists of a Manifold Absolute Pressure (MAP) sensor and an integrated thermistor. The thermistor part of the sensor is currently not being used. The MAP part of the sensor measures intake manifold air absolute pressure. The PCM uses information from the MAP sensor, Throttle Position (TP) sensor, Mass Air Flow (MAF) sensor, Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CKP) sensor and Crankshaft Position (CKP) sensor to determine how much exhaust gas is introduced into the intake manifold. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications Mass Air Flow Sensor: Specifications Mass Air Flow Sensor Nuts And Bolts 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3946 Mass Air Flow Sensor: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3947 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3948 Mass Air Flow Sensor: Description and Operation MASS AIR FLOW SENSOR Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3949 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Loosen the air cleaner outlet tube clamp and position aside. 4. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation Intake Air Temperature Sensor: Description and Operation INTAKE AIR TEMPERATURE SENSOR Intake Air Temperature (IAT) Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire Terminals The Intake Air Temperature (IAT) sensors (Figure 34) and integrated Mass Air Flow (MAF) type (Figure 37), are thermistor devices in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Page 3953 Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel spark and MAF. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Supercharged 5.4L Lightning vehicles use (2) AT sensors. Both sensors operate as above. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor Second Intake Air Temperature (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle Technical Service Bulletin # 03-3-5 Date: 030217 Engine Controls - No Start/Hard Start/Rough Idle Article No. 03-3-5 02/17/03 DRIVEABILITY - IDLE AIR CONTROL (IAC) VALVE DIAGNOSTIC SERVICE TIPS FORD: 2000-2003 TAURUS 2002 THUNDERBIRD 2000-2003 EXPLORER, RANGER 2001-2003 EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 2000-2002 LS MERCURY: 2000-2003 SABLE, MOUNTAINEER ISSUE Some vehicles, may exhibit drivability conditions. These may include: ^ No start Difficult to start Stall ^ Low idle ^ Rough idle ^ High idle ^ Hesitation/surge while accelerating or at steady speed These conditions may be intermittent with no Diagnostic Trouble Codes (DTC) and no Malfunction Indicator Lamp (MIL). In some cases DTC and MIL may be evident. ACTION Trouble cannot be identified with 95% of returned Idle Air Control (IAC) valves. The following procedure is supplemental information to normal diagnostics to facilitate accurate identification of malfunctioning valves. These symptoms would include engine stall, hard start, crank/no start, idling problems, and Idle Speed Control System related DTC's. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3962 If the service writer uses the worksheet (Figure 2) for all drivability concerns including stalls it will assist the technician making a correct repair the first time. Perform normal diagnostics. SERVICE INFORMATION NOTE Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3963 IT MAY NOT BE POSSIBLE TO DUPLICATE THE CUSTOMER CONCERN. ALTHOUGH THE CONDITION MAY NOT BE DUPLICATED, IT IS RECOMMENDED THAT ANY EVALUATION OF THE IAC VALVE BE DONE IN ACCORDANCE WITH THE FOLLOWING SERVICE PROCEDURE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 602300 603300, 607000, 607400, 607700, 608000, 608400, 611000, 618400, 619400, 698298 Disclaimer IAC Diagnostic Service Tips - General Never clean an IAC valve. Carburetor cleaners and other cleaning agents may temporarily repair the drivability concern, but the long-term functionality of the valve is compromised. For all drivability concerns, make certain the service writer obtains as much information as possible from the customer as to the conditions causing drivability concern. Attached is a drivability concern check off sheet (Figure 2) that if used, can help reduce the time required to diagnose a vehicle. NOTE IF THE ENGINE STALLED WHILE THE VEHICLE WAS IN GEAR AND MOVING THE POSSIBILITY OF THE IAC VALVE CAUSING THIS IS UNLIKELY UNLESS IT OCCURRED ON DECELERATION. Use the following Supplemental information for 3.0L 4V Duratec Engines, in the Taurus/Sable, and Lincoln LS. 1. Use the following conditions for the test described below: ^ Transmission in park ^ Engine temperature should be at least 190° F (88°C) ^ All accessories should be off steering wheel in the center position ^ EGVR and EVAPDUTY CYCLE at zero, if the vehicle has an EGR system ^ Short and long term fuel trims less than 15% ^ At stabilized engine speed (RPM) and temperature (hot idle) per the Powertrain Control Emission Diagnostics (PC/ED) manual, verify the IAC duty cycle is within reference values called out in the chart in this TSB. NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure that there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. Use the following Supplemental Information for the 3.9L Lincoln LS and Thunderbird. 1. Use the following conditions for the test described below: ^ Transmission in park Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3964 ^ Engine idle at approximately 650 RPM ^ Engine temperature should be at least 190° F (88° C) ^ All accessories and the engine cooling fan should be off ^ Steering wheel in the center position ^ EGRVR and EVAPDUTY CYCLE are zero ^ Short and long term fuel trims less than 15% NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. NOTE IT IS EXTREMELY IMPORTANT TO CHECK THE IAC DUTY CYCLE WHEN THE RPM IS AT 650 RPM. EVEN 700 RPM IS TOO HIGH FOR CHECKING the IAC VALVE DUTY CYCLE UNDER THESE CONDITIONS. IF THE RPM IS OVER 650 RPM, MOMENTARILY OPENING AND CLOSING THE THROTTLE AND A SHORT EQUILIBRATION TIME WILL LOWER THE RPM. At stabilized engine speed and temperature, verify that the IAC duty cycle is between 27-36% with no purge flow (EVAPV duty cycle is 0%). If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. NOTE IF THE ORIGINAL IAC VALVE WAS WITHIN DUTY CYCLE SPECIFICATION OR THE DUTY CYCLE REMAINS OUT OF SPECIFICATIONS AFTER IAC VALVE REPLACEMENT FURTHER DIAGNOSTICS ARE REQUIRED TO ADDRESS THE CUSTOMER CONCERN. Use the following Supplemental Information for 4.0L SOHC Engines In the Ranger, Explorer, Mountaineer, Explorer Sport and Explorer Sport Trac. If no DTC's present check the following items in this order before examining the IAC valve: ^ BARO Hz reading - Refer to Barometric Pressure Chart listed in this TSB ^ Battery and fuse box power lead ^ Ground wire attachments ^ Wiring (wiggle test) ^ PCM voltage ^ Vacuum leaks Examine AC valve under these conditions: ^ PCM updated to the latest available calibration ^ Transmission in park ^ Warm stabilized vehicle with engine temperature at least 190° F (88° C) ^ All accessories and cooling fan sh6uld be off Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3965 ^ Steering wheel in the center position ^ EGVR and EVAPDC at zero, if the vehicle has an EGR system ^ Short and long term fuel trims (less than 15) Perform the following steps in order: 1. Using either NGS or WDS bring up the following PIDS: IACTRIM, IACKAM2, IACKAM3. 2. Allow vehicle to idle until the IACTRIM PID is 0. NOTE IACTRIM ALWAYS TRIES TO GO TO 0. WHEN MOVING TOWARDS 0, THE IACKAM2 PID SHOULD BE CHANGING. IF IACKAM3 IS CHANGING, THEN THE AIR CONDITIONING SHOULD BE TURNED OFF. 3. If IACKAM2 is between -0.35 and +0.35 with IACTRIM=0, then the valve is operating properly at idle. The remainder of this TSB will help diagnose true root cause. 4. If IACKAM2 is not between -0.35 and +0.35, it is highly likely that the engine idle system (to include the throttle body and air intake system) -is not operating properly. NOTE FOR ALL VEHICLES PLEASE RECORD THE OBSERVED IAC DUTY CYCLE AND ENGINE RPM IN THE WARRANTY CLAIMS COMMENTS FOR THIS DIAGNOSTIC. IAC Diagnostic Service Tips - DTC 1506 (IAC Over Speed Error) and other High Idle Concerns: ^ There are two primary causes of high idle: 1. Damaged IAC valves and 2. Vacuum leaks ^ AC valves can be damaged from engine induction backfires. Many times the customer may not notice the induction backfire but will notice the high idle afterwards. Indications of valve damage can be a shiny, almost polished appearance in the interior of the valve and a dislocated Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3966 pintle. An IAC valve damaged by backfire should be replaced. Refer to Figure 1. ^ Inspect PCV system for leaks especially looking for cracks along any rubber elbow joints; also verify that the correct PCV valve is installed. ^ Inspect for vacuum hoses loose or disconnected from intended ports and connections. Induction backfire can loosen or disconnect vacuum hoses. ^ Two indicators can help you identify if a vacuum leak is present, even if the engine RPM appear normal in the service bay. If the duty cycle is below specification that is indicative that the engine is receiving too much air (from a vacuum leak) and the PCM is ordering the valve to close up to restrict flow. Another indication is fuel trim. Record the long term and short term fuel trim PIDS (LONGFT1, LONGFT2, SHORTFT1, etc.), if short term fuel trims are high (above specification) this is a possible indication of a vacuum leak, making the engine run lean, and the PCM is attempting to compensate. IAC Diagnostic Service Tips - DTC 1507 (IAC Under Speed Error) and Other Low Idle Concerns: ^ An under speed error may not necessarily be a fault with the IAC valve. A large friction load on the engine or obstruction in the air intake system could also reduce the engine RPMs. ^ There are four possible sources of friction load that can contribute to under speed error or low idle concerns. 1. Power Steering Load 2. Air Conditioning Load 3. Electrical Load 4. Automatic Transmission Torque Converter Load EAC Diagnostic Service Tips - Rough Idle Concerns: ^ Rough idle concerns are often a result of a lean running condition ^ Another possible cause is contamination build up on the MAF sensor EAC Diagnostic Service Tips - Engine Hard Start/Engine Crank-No Start ^ While performing diagnostics, the technician should ensure that the fuel system is working correctly for all engines with hard start/crank no-start complaints. ^ When diagnosing a mechanical return less fuel system, the following correction to the PC/ED pinpoint HC (4) diagnostic procedure should be used when performing the KEOE fuel pressure test: ^ Perform the KOEO fuel pressure test as specific in the PC/ED manual. ^ The fuel pressure should drop off no more than 10 psi from maximum pressure (no lower than 55 psi for a 65 psi max system or no lower than 45 psi for a 55 psi max system) within 5 minutes of the start of the test. ^ The fuel pressure should drop off to no less than 30 psi within 30 minutes of the start of the test. ^ For greatest accuracy, the service technician should read the fuel pressure as soon as possible after pump shut off, no more than 5 minutes after the start of the test. NOTE RETURNABLE AND ELECTRONIC RETURN LESS SYSTEMS SHOULD ALSO BE DIAGNOSED USING THE PROCEDURES LISTED FOR THEM IN PINPOINT TEST HC. IAC Diagnostic Service Tips - High Idle RPM at Start Up: ^ Most engines will have a temporary high idle at engine start up to allow for catalyst light off. If DTC 1506 is not present, this indicates that there is no fault present with the IAC. ^ A vehicle with very low odometer miles, may exhibit a higher than normal temporary startup fast idle (1600-2500 RPM that decreases slowly). No Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3967 repairs should be attempted because this is a normal temporary PCM calibration strategy to prevent spark plug fouling during plant/transportation operation. The calibration will permanently revert to its normal strategy after the PCM has seen its first 4 miles of continuous drive cycle. A brand new vehicle may accumulate some mileage without turning this strategy off if the drive cycle has been below 4 miles at a time. IAC Diagnostic Service Tips - EAC Valve Noise Issues For IAC valve noise concerns check for obstructed or potentially damaged IAC valve from backfire. NOTE Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3968 ON SOME NEWER MODEL YEAR VEHICLES THE REACTION SPEED OF THE EAC VALVE IS FAST ENOUGH THAT IT MIGHT MAKE A "POPPING" SOUND AS IT REACTS TO A LARGE IDLE LOAD. THIS IS A NORMAL CHARACTERISTIC AND NO ATTEMPTS SHOULD BE MADE IN AN EFFORT TO MODIFY THE PERFORMANCE OF THE IAC VALVE. IF POSSIBLE, COMPARE AGAINST A LIKE VEHICLE. 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. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle Technical Service Bulletin # 03-3-5 Date: 030217 Engine Controls - No Start/Hard Start/Rough Idle Article No. 03-3-5 02/17/03 DRIVEABILITY - IDLE AIR CONTROL (IAC) VALVE DIAGNOSTIC SERVICE TIPS FORD: 2000-2003 TAURUS 2002 THUNDERBIRD 2000-2003 EXPLORER, RANGER 2001-2003 EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 2000-2002 LS MERCURY: 2000-2003 SABLE, MOUNTAINEER ISSUE Some vehicles, may exhibit drivability conditions. These may include: ^ No start Difficult to start Stall ^ Low idle ^ Rough idle ^ High idle ^ Hesitation/surge while accelerating or at steady speed These conditions may be intermittent with no Diagnostic Trouble Codes (DTC) and no Malfunction Indicator Lamp (MIL). In some cases DTC and MIL may be evident. ACTION Trouble cannot be identified with 95% of returned Idle Air Control (IAC) valves. The following procedure is supplemental information to normal diagnostics to facilitate accurate identification of malfunctioning valves. These symptoms would include engine stall, hard start, crank/no start, idling problems, and Idle Speed Control System related DTC's. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3974 If the service writer uses the worksheet (Figure 2) for all drivability concerns including stalls it will assist the technician making a correct repair the first time. Perform normal diagnostics. SERVICE INFORMATION NOTE Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3975 IT MAY NOT BE POSSIBLE TO DUPLICATE THE CUSTOMER CONCERN. ALTHOUGH THE CONDITION MAY NOT BE DUPLICATED, IT IS RECOMMENDED THAT ANY EVALUATION OF THE IAC VALVE BE DONE IN ACCORDANCE WITH THE FOLLOWING SERVICE PROCEDURE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 602300 603300, 607000, 607400, 607700, 608000, 608400, 611000, 618400, 619400, 698298 Disclaimer IAC Diagnostic Service Tips - General Never clean an IAC valve. Carburetor cleaners and other cleaning agents may temporarily repair the drivability concern, but the long-term functionality of the valve is compromised. For all drivability concerns, make certain the service writer obtains as much information as possible from the customer as to the conditions causing drivability concern. Attached is a drivability concern check off sheet (Figure 2) that if used, can help reduce the time required to diagnose a vehicle. NOTE IF THE ENGINE STALLED WHILE THE VEHICLE WAS IN GEAR AND MOVING THE POSSIBILITY OF THE IAC VALVE CAUSING THIS IS UNLIKELY UNLESS IT OCCURRED ON DECELERATION. Use the following Supplemental information for 3.0L 4V Duratec Engines, in the Taurus/Sable, and Lincoln LS. 1. Use the following conditions for the test described below: ^ Transmission in park ^ Engine temperature should be at least 190° F (88°C) ^ All accessories should be off steering wheel in the center position ^ EGVR and EVAPDUTY CYCLE at zero, if the vehicle has an EGR system ^ Short and long term fuel trims less than 15% ^ At stabilized engine speed (RPM) and temperature (hot idle) per the Powertrain Control Emission Diagnostics (PC/ED) manual, verify the IAC duty cycle is within reference values called out in the chart in this TSB. NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure that there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. Use the following Supplemental Information for the 3.9L Lincoln LS and Thunderbird. 1. Use the following conditions for the test described below: ^ Transmission in park Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3976 ^ Engine idle at approximately 650 RPM ^ Engine temperature should be at least 190° F (88° C) ^ All accessories and the engine cooling fan should be off ^ Steering wheel in the center position ^ EGRVR and EVAPDUTY CYCLE are zero ^ Short and long term fuel trims less than 15% NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. NOTE IT IS EXTREMELY IMPORTANT TO CHECK THE IAC DUTY CYCLE WHEN THE RPM IS AT 650 RPM. EVEN 700 RPM IS TOO HIGH FOR CHECKING the IAC VALVE DUTY CYCLE UNDER THESE CONDITIONS. IF THE RPM IS OVER 650 RPM, MOMENTARILY OPENING AND CLOSING THE THROTTLE AND A SHORT EQUILIBRATION TIME WILL LOWER THE RPM. At stabilized engine speed and temperature, verify that the IAC duty cycle is between 27-36% with no purge flow (EVAPV duty cycle is 0%). If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. NOTE IF THE ORIGINAL IAC VALVE WAS WITHIN DUTY CYCLE SPECIFICATION OR THE DUTY CYCLE REMAINS OUT OF SPECIFICATIONS AFTER IAC VALVE REPLACEMENT FURTHER DIAGNOSTICS ARE REQUIRED TO ADDRESS THE CUSTOMER CONCERN. Use the following Supplemental Information for 4.0L SOHC Engines In the Ranger, Explorer, Mountaineer, Explorer Sport and Explorer Sport Trac. If no DTC's present check the following items in this order before examining the IAC valve: ^ BARO Hz reading - Refer to Barometric Pressure Chart listed in this TSB ^ Battery and fuse box power lead ^ Ground wire attachments ^ Wiring (wiggle test) ^ PCM voltage ^ Vacuum leaks Examine AC valve under these conditions: ^ PCM updated to the latest available calibration ^ Transmission in park ^ Warm stabilized vehicle with engine temperature at least 190° F (88° C) ^ All accessories and cooling fan sh6uld be off Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3977 ^ Steering wheel in the center position ^ EGVR and EVAPDC at zero, if the vehicle has an EGR system ^ Short and long term fuel trims (less than 15) Perform the following steps in order: 1. Using either NGS or WDS bring up the following PIDS: IACTRIM, IACKAM2, IACKAM3. 2. Allow vehicle to idle until the IACTRIM PID is 0. NOTE IACTRIM ALWAYS TRIES TO GO TO 0. WHEN MOVING TOWARDS 0, THE IACKAM2 PID SHOULD BE CHANGING. IF IACKAM3 IS CHANGING, THEN THE AIR CONDITIONING SHOULD BE TURNED OFF. 3. If IACKAM2 is between -0.35 and +0.35 with IACTRIM=0, then the valve is operating properly at idle. The remainder of this TSB will help diagnose true root cause. 4. If IACKAM2 is not between -0.35 and +0.35, it is highly likely that the engine idle system (to include the throttle body and air intake system) -is not operating properly. NOTE FOR ALL VEHICLES PLEASE RECORD THE OBSERVED IAC DUTY CYCLE AND ENGINE RPM IN THE WARRANTY CLAIMS COMMENTS FOR THIS DIAGNOSTIC. IAC Diagnostic Service Tips - DTC 1506 (IAC Over Speed Error) and other High Idle Concerns: ^ There are two primary causes of high idle: 1. Damaged IAC valves and 2. Vacuum leaks ^ AC valves can be damaged from engine induction backfires. Many times the customer may not notice the induction backfire but will notice the high idle afterwards. Indications of valve damage can be a shiny, almost polished appearance in the interior of the valve and a dislocated Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3978 pintle. An IAC valve damaged by backfire should be replaced. Refer to Figure 1. ^ Inspect PCV system for leaks especially looking for cracks along any rubber elbow joints; also verify that the correct PCV valve is installed. ^ Inspect for vacuum hoses loose or disconnected from intended ports and connections. Induction backfire can loosen or disconnect vacuum hoses. ^ Two indicators can help you identify if a vacuum leak is present, even if the engine RPM appear normal in the service bay. If the duty cycle is below specification that is indicative that the engine is receiving too much air (from a vacuum leak) and the PCM is ordering the valve to close up to restrict flow. Another indication is fuel trim. Record the long term and short term fuel trim PIDS (LONGFT1, LONGFT2, SHORTFT1, etc.), if short term fuel trims are high (above specification) this is a possible indication of a vacuum leak, making the engine run lean, and the PCM is attempting to compensate. IAC Diagnostic Service Tips - DTC 1507 (IAC Under Speed Error) and Other Low Idle Concerns: ^ An under speed error may not necessarily be a fault with the IAC valve. A large friction load on the engine or obstruction in the air intake system could also reduce the engine RPMs. ^ There are four possible sources of friction load that can contribute to under speed error or low idle concerns. 1. Power Steering Load 2. Air Conditioning Load 3. Electrical Load 4. Automatic Transmission Torque Converter Load EAC Diagnostic Service Tips - Rough Idle Concerns: ^ Rough idle concerns are often a result of a lean running condition ^ Another possible cause is contamination build up on the MAF sensor EAC Diagnostic Service Tips - Engine Hard Start/Engine Crank-No Start ^ While performing diagnostics, the technician should ensure that the fuel system is working correctly for all engines with hard start/crank no-start complaints. ^ When diagnosing a mechanical return less fuel system, the following correction to the PC/ED pinpoint HC (4) diagnostic procedure should be used when performing the KEOE fuel pressure test: ^ Perform the KOEO fuel pressure test as specific in the PC/ED manual. ^ The fuel pressure should drop off no more than 10 psi from maximum pressure (no lower than 55 psi for a 65 psi max system or no lower than 45 psi for a 55 psi max system) within 5 minutes of the start of the test. ^ The fuel pressure should drop off to no less than 30 psi within 30 minutes of the start of the test. ^ For greatest accuracy, the service technician should read the fuel pressure as soon as possible after pump shut off, no more than 5 minutes after the start of the test. NOTE RETURNABLE AND ELECTRONIC RETURN LESS SYSTEMS SHOULD ALSO BE DIAGNOSED USING THE PROCEDURES LISTED FOR THEM IN PINPOINT TEST HC. IAC Diagnostic Service Tips - High Idle RPM at Start Up: ^ Most engines will have a temporary high idle at engine start up to allow for catalyst light off. If DTC 1506 is not present, this indicates that there is no fault present with the IAC. ^ A vehicle with very low odometer miles, may exhibit a higher than normal temporary startup fast idle (1600-2500 RPM that decreases slowly). No Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3979 repairs should be attempted because this is a normal temporary PCM calibration strategy to prevent spark plug fouling during plant/transportation operation. The calibration will permanently revert to its normal strategy after the PCM has seen its first 4 miles of continuous drive cycle. A brand new vehicle may accumulate some mileage without turning this strategy off if the drive cycle has been below 4 miles at a time. IAC Diagnostic Service Tips - EAC Valve Noise Issues For IAC valve noise concerns check for obstructed or potentially damaged IAC valve from backfire. NOTE Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 3980 ON SOME NEWER MODEL YEAR VEHICLES THE REACTION SPEED OF THE EAC VALVE IS FAST ENOUGH THAT IT MIGHT MAKE A "POPPING" SOUND AS IT REACTS TO A LARGE IDLE LOAD. THIS IS A NORMAL CHARACTERISTIC AND NO ATTEMPTS SHOULD BE MADE IN AN EFFORT TO MODIFY THE PERFORMANCE OF THE IAC VALVE. IF POSSIBLE, COMPARE AGAINST A LIKE VEHICLE. 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. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor, Stud Bolt 19 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3984 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3985 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3986 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the CMP sensor electrical connector. 2 Remove the CMP sensor stud bolt. 3 Remove the camshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams > Page 3990 Clutch Switch: Description and Operation CLUTCH PEDAL POSITION SWITCH Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch (Figure 24) is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference Vehicle Reference Voltage (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 15 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3994 Coolant Temperature Sensor/Switch (For Computer): Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3995 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3996 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Remove the thermostat and housing. For additional information, refer to Cooling System. 2. Disconnect the battery ground cable. For additional information, refer to Battery. 3. Remove the Engine Coolant Temperature (ECT) sensor. 1 Disconnect the connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolts 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 4000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Electronic Engine Controls Crankshaft Position Sensor: Description and Operation Electronic Engine Controls The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Electronic Engine Controls > Page 4003 Crankshaft Position Sensor: Description and Operation Standard Models (Non BI-Fuel) CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference (Figure 25). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Page 4004 Crankshaft Position Sensor: Service and Repair REMOVAL NOTE: The 5.0L is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Crankshaft Position (CKP) sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ 4.0L SOHC and 4.0L (push rod) CKP sensors need to be touching the damper. The CKP sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure sensor wiring is routed away from the battery cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions Data Link 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4010 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4011 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4012 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4013 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4014 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4015 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4016 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4017 Data Link Connector: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4018 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4019 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4020 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4021 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4022 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4023 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 4024 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Page 4025 Data Link Connector: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Module Communications Network / Information Bus. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures Powertrain Control Module: Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 4030 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 4031 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4032 Powertrain Control Module: Specifications PCM Connector 5 - 7 Nm Powertrain Control Module Connector Bolt 7 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4033 Powertrain Control Module: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4034 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4035 Powertrain Control Module: Diagrams Part (1 Of 3) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4036 Part (2 Of 3) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4037 Part (3 Of 3) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > General Description and Operation Powertrain Control Module: Description and Operation General Description and Operation The PCM performs the following functions: ^ accepts input from various engine sensors to compute the required fuel flow rate necessary to maintain a prescribed air/fuel ratio throughout the entire engine operational range. ^ outputs a command to the fuel injectors to meter the appropriate quantity of fuel. ^ determines and compensates for the age of the vehicle and its uniqueness, also automatically senses and compensates for changes in altitude. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > General Description and Operation > Page 4040 Powertrain Control Module: Description and Operation Standard Models (Non BI-Fuel) POWERTRAIN CONTROL MODULE - VEHICLE SPEED OUTPUT (VSO) The PCM-VSO (Powertrain Control Module - Vehicle Speed Output) speed signal subsystem generates vehicle speed information for distribution to the vehicle's electrical/electronic modules and subsystems that require vehicle speed data. This subsystem senses the transmission output shaft speed with a sensor. The data is processed by the PCM, and distributed as a hard-wired signal or as a multiplexed data message. The key features of the PCM-VSO system are to: ^ Infer vehicle movement from the output shaft sensor signal ^ Convert transmission output shaft rotational information to vehicle speed information ^ Compensate for tire size and axle ratio with a programmed calibration variable ^ Utilize a transfer case sensor for four wheel drive applications ^ Distribute vehicle speed information as a multiplexed message and/or an analog signal The signal from a non-contact shaft sensor (Output Shaft Sensor--OSS or Transfer Case Shaft Sensor--TCSS) mounted on the transmission (automatics, manuals, or 4X4 transfer cases) is sensed directly by the PCM. The PCM converts the OSS or TCSS information to 8000 pulses per mile, based on a tire and axle ratio conversion factor. This conversion factor is programmed into the PCM at the time the vehicle is assembled and can be reprogrammed in the field for servicing changes in the tire size and axle ratio. The PCM transmits the computed vehicle speed and distance traveled information to all the vehicle speed signal users on the vehicle. VSO information can be transmitted by a hard-wired interface between the vehicle speed signal user and the PCM, or by Speed and Odometer SCP multiplexed data messages. The VSO hard-wired signal wave form is a DC square wave with a voltage level of 0 to VBAT. Typical output operating range is 2.22Hz per MPH (1.3808 Hz pr 1 Km/h). Multiplexed data for speed and distance data are transmitted as separate SCP messages over the SCP multiplex link. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Flash Electrically Eraseable Programmable Read Only Memory Powertrain Control Module: Service and Repair Flash Electrically Eraseable Programmable Read Only Memory Flash Electrically Eraseable Programmable Read Only Memory - Flash EEPROM Description Flash Electrically Eraseable Programmable Read Only Memory (EEPROM) is contained in an Integrated Circuit (IC) internal to the Powertrain Control Module (PCM). The EEPROM contains the vehicle strategy including calibration information specific to the vehicle and is capable of being reprogrammed or reflashed repeatedly. As part of the calibration there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM as under Programming the VID Block for a Replacement PCM. Failure to perform this procedure may generate fault code: P1639, VID Block not programmed or is corrupt. The VID block in an existing Powertrain Control Module (PCM). can also be tailored to accommodate various hardware changes made to the vehicle since production. Failure to perform this procedure properly may generate fault code: P1635, Tire/Axle Ratio out of Acceptable Range. This is described under Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the VIN number, octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control and four wheel drive electronic shift on the fly versus manual shift on the fly. Only items applicable to vehicle hardware and supported by the VID block will be displayed on the scan tool. When changing items in the VID block, the strategy will place range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool will display a message indicating the need to flash the PCM again to reset the VID block. Each of the procedures described below use the Worldwide Diagnostic System (WDS). Reprogramming can be performed by a local Ford dealer for any non Ford facility. There are other Enhanced Scan Tools that may have reprogramming capabilities available. Refer to the diagnostic tool manufacturers users manual for details. Programming the VID Block for a Replacement PCM A new PCM will contain the latest strategy and calibration level for a particular vehicle. However, the VID block will be blank and will need programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM and the second is manual data entry into the new PCM. Automatic data transfer will be performed if the old PCM is capable of communicating. This is done by the use of a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can now be downloaded to the new PCM after it has been replaced. Manual data entry must be performed if the old module is damaged and is incapable of communicating. Remove and replace the old PCM. You may be instructed to contact the "AS BUILT" data center for the information needed to manually update the VID block with the scan tool. Contact the center ONLY if the old PCM cannot be used or the data is corrupt. For Ford L-M technician's, contact your National Hotline for "AS Built" data. Non Ford technicians, use the Fed World website at "fedworld.gov". Select Auto Service Information and search for "Calibrations" or "Vehicle Calibrations" then specify vehicle manufacturer, model name and model year as required. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate vehicle hardware. Refer to PCM/Module Reprogramming on the Scan Tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM will need to be completely reprogrammed. This is due to changes made to the strategy or calibration after production or the need to reset the VID block because it has reached its limit. Refer to PCM/Module Reprogramming on the Scan Tool. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Flash Electrically Eraseable Programmable Read Only Memory > Page 4043 Powertrain Control Module: Service and Repair Removal and Installation REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Powertrain Control Module (PCM) electrical connector. 3. Remove the nuts and the PCM cover. 4. Remove the PCM. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor CYLINDER HEAD TEMPERATURE SENSOR Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy details. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor > Page 4048 Engine Temperature Sensor: Description and Operation Engine Coolant Temperature (ECT) Sensor ENGINE COOLANT TEMPERATURE (ECT) SENSOR Engine Coolant Temperature (ECT) Sensor The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation The fuel sending unit is a variable resistor made up of a ceramic substrate. It is controlled by the action of a float arm. When the fuel level is low, resistance in the unit is low. When the fuel level is high, the resistance is high. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Pump Signal > Component Information > Description and Operation Fuel Pump Signal: Description and Operation FUEL PUMP MONITOR Applications Using a Fuel Pump Relay for Fuel Pump On/Off Control The Fuel Pump Monitor (FPM) circuit is spliced into the Fuel Pump Power (FP PWR) circuit and is used by the PCM for diagnostic purposes. The PCM sources a low current voltage down the FPM circuit. With the fuel pump off, this voltage is pulled low by the path to ground through the fuel pump. With the fuel pump off and the FPM circuit low, the PCM can verify that the FPM circuit and the FP PWR circuit are complete from the FPM splice through the fuel pump to ground. This also confirms that the FP PWR or FPM circuits are not shorted to power. With the fuel pump on, voltage is now being supplied from the fuel pump relay to the FP PWR and FPM circuits. With the fuel pump on and the FPM circuit high, the PCM can verify that the FP PWR circuit from the fuel pump relay to the FPM splice is complete. It can also verify that the fuel pump relay contacts are closed and there is a B+ supply to the fuel pump relay. Fuel Pump Driver Module Applications Fuel Pump Driver Module Duty Cycle Signals, Part 1 Fuel Pump Driver Module Duty Cycle Signals, Part 2 The Fuel Pump Driver Module (FPDM) communicates diagnostic information to the Powertrain Control Module (PCM) through the Fuel Pump Monitor (FPM) circuit. This information is sent by the FPDM as a duty cycle signal. The three duty cycle signals that may be sent are listed in the table. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 4058 Fuel Tank Pressure Sensor: Service Precautions CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 4059 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The Fuel Tank Pressure (FTP) sensor (Figure 97) or inline Fuel Tank Pressure (FTP) sensor (Figure 98) is used to measure the fuel tank pressure during the EVAP monitor test on vehicles equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank pressure by forcing the system to purge. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 4060 Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Remove the fuel tank. For additional information, refer to Fuel Delivery and Air Induction. 2. Remove the fuel tank pressure sensor. 1 Disconnect the electrical connector. 2 Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the fuel tank. CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. INSTALLATION 1. To install, reverse removal procedure. ^ Leak test the evaporative emission system. For additional information, refer to Evaporative Emission System Leak Test System. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emissions repair verification drive cycle. For additional information, refer to Evaporative Emission Repair Verification Drive Cycle. See: Emission Control Systems/Evaporative Emissions System/Service and Repair Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications Idle Air Control Valve: Specifications Idle Air Control Valve Bolts 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 4064 Idle Air Control Valve: Description and Operation IDLE AIR CONTROL VALVE Nippondenso Idle Air Control (IAC) Valve Assembly Hitachi Idle Air Control (IAC) Valve Assembly With Vent/Filter The Idle Air Control (IAC) valve assembly (Figure 117) and (Figure 118) controls engine idle speed and provides a dashpot function. The IAC valve assembly meters intake air around the throttle plate through a bypass within the IAC valve assembly and throttle body. The PCM determines the desired idle speed or bypass air and signals the IAC valve assembly through a specified duty cycle. The IAC valve responds by positioning the IAC valve to control the amount of bypassed air. The PCM monitors engine rpm and increases or decreases the IAC duty cycle in order to achieve the desired rpm. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 4065 Hitachi Idle Air Control (IAC) Valve Assembly With Air-Assist Injectors On applications with air-assisted injectors, the IAC valve (Figure 119) also supplies a small amount of air into the path of the fuel injectors. The jet of air causes an increase in fuel atomization at low speed and light load conditions. NOTE: The IAC Valve Assembly is NOT ADJUSTABLE and CANNOT BE CLEANED. The IAC valve (part of throttle body assembly) has an internal diode on some applications. If the internal diode is measured in crossed terminal position with a digital multimeter, there will be an incorrect or negative reading. It is important that the mating component and harness connectors correctly oriented. Diagnostic procedures emphasize this importance. The PCM uses the IAC valve assembly to control: ^ No touch start ^ Cold engine fast idle for rapid warm-up ^ Idle (corrects for engine load) ^ Stumble or stalling on deceleration (provides a dashpot function) ^ Over-temperature idle boost. ^ Air Assist to Injectors. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 4066 Idle Air Control Valve: Testing and Inspection 1. Open the hood. 2. Verify the condition by operating the vehicle for a short time. NOTE: ^ Key symptom is elevated idle speed while noise is occurring. ^ "Snapping" the throttle can induce the noise. 3. Inspect the IAC valve. If physical evidence of contamination exists, install a new IAC valve. 4. While the noise is occurring, either place an Engine EAR probe near the IAC valve and the inlet tube, or create a 6.35 mm (0.25 in) - 12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the IAC valve is making the noise, install a new IAC valve. 5. Test the vehicle for normal operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 4067 Idle Air Control Valve: Service and Repair REMOVAL NOTE: The 5.0L is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the accelerator control snow shield. 3. Disconnect the idle air control (IAC) valve electrical connector. 4. Remove the IAC valve and discard the gasket. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Install a new IAC valve gasket. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Specifications Multiplex Communication Network: Specifications Heat shrink tube overlap 12.7 mm Wire insulation removal length (twist side) 37.2 mm Wire insulation removal length (receiving side) 19.5 mm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Specifications > Page 4071 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions Multiplex Communication Network: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4074 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4075 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4076 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4077 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4078 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4079 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4080 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4081 Multiplex Communication Network: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4082 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4083 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4084 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4085 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4086 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4087 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4088 Diagram 14-1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Description and Operation > Description and Operation Multiplex Communication Network: Description and Operation The vehicle has two separate module communication networks. The Standard Corporate Protocol (SCP) which is an unshielded twisted pair cable (data bus plus, circuit 914 [T/O] and data bus minus, circuit 915 [P/LB]) and the International Standards Organization (ISO) 9141 Network via a single wire (circuit 70 [LB/W]). Both networks can be connected to scan tool at one connector called the Data Link Connector (DLC). This makes troubleshooting these systems easier by allowing one smart tester to be able to diagnose and control any module on the two networks from one connector. The DLC can Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Description and Operation > Description and Operation > Page 4091 be found under the instrument panel between the steering column and the radio. The ISO 9141 communication network does not permit inter-module communication. When the scan tool communicates to modules on the ISO 9141 communication network, the scan tool must ask for all information; the modules cannot initiate communications. The SCP will remain operational even with the severing of one of the bus wires. Communications will also continue if one of the bus wires is shorted to ground or battery positive voltage (B+) or a termination resistor is lost. This faulted condition is detected and reported to the host by the module's network bus interface circuits. Unlike the SCP, the ISO 9141 communication network will not function if the wire is shorted to ground or battery positive voltage (B+). Also, if one of the modules on the ISO 9141 communication network loses power or shorts internally, communications to that module will fail. There are three modules linked to the SCP communication network and seven modules linked to the ISO 9141 communication network. SCP Communication Network The Powertrain Control Module (PCM) is on the SCP communication network. The PCM controls the engine for better fuel economy, emissions control and failure mode detection and storage. The Passive Anti-theft System (PATS) module is on the SCP communication network. The PATS module contains circuitry to connect the vehicle electrical system, the transceiver module, the vehicle module communications network and the vehicle theft indicator located in the instrument cluster. The PATS module uses a microprocessor to control the system functions. The PATS module microprocessor stores the ignition key codes in non-volathe memory. The PATS module can be diagnosed through the data link connector. For additional information, refer to Antitheft and Alarm Systems. The Electronic Automatic Temperature Control (EATC) module is linked to the SCP communication network. The EATC module controls automatic climate functions that maintain the interior at a constant temperature setting. For additional information, refer to Heating and Air Conditioning. ISO 9141 Communication Network The Restraint Control Module (RCM) module is on the ISO 9141 communication network. The RCM controls the deployment of the air bags based on sensor input. For additional information, refer to Air Bag Systems. The Parking Aid Module (PAM) is on the ISO 9141 communication network. The PAM controls the parking aid system For additional information, See: Accessories and Optional Equipment/Collision Avoidance and Parking Assist Systems The Generic Electronic Module (GEM)/Central Timer Module (CTM) is on the ISO 9141 communication network. The GEM is equipped on vehicles with four-wheel drive or vehicles with power windows. The CTM is equipped on vehicles with two-wheel drive or vehicles without power windows. The GEM controls a variety of systems: ^ 4x4 ^ Windshield wipers ^ Courtesy lamps ^ One touch down power windows, etc. ^ Warning chimes/lamps For additional information, refer to Multifunction Electronic Control Module. The Remote Anti-theft Personality (RAP) module is on the ISO 9141 communication network. The RAP module controls the keyless remote entry and active anti-theft of the vehicle. For additional information, refer to Keyless Entry and Antitheft and Alarm Systems. The 4-wheel anti-lock brake control module is on the ISO 9141 communication network. The 4-wheel anti-lock brake control module controls the brake pressure to the four wheels to keep the vehicle under control while braking. For additional information, refer to Antilock Brake System. The air suspension system is a computer controlled suspension system. The rear shock absorber contains an integrated air spring. The rear air springs provide automatic load leveling and a ride adjustment with a total span of 50 mm (2 in). The air suspension control module programming has a time delay compensation for normal suspension travel over rough roads so the air suspension system will not attempt to continuously adjust vehicle ride height. There is one height sensor mounted in the rear of the vehicle. The height sensors have a total travel range of 80 mm (3 in). For additional information, refer to Electronic Level Control. The Driver Seat Module (DSM) is connected on the SCP communication network. The DSM controls the power seat and memory functions. For additional information, refer to Seats. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Description and Operation > Description and Operation > Page 4092 Multiplex Communication Network: Description and Operation Principles of Operation Some modules support the ability to change specified factory configuration settings and preset preference items. The process used to change the settings and customer preference items is module configuration. The methods of module configuration used on these vehicles are: ^ Tire Size and Axle Ratio ^ Operational Strategy (4x2/4x4) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network Multiplex Communication Network: Testing and Inspection Module Communications Network Initial Inspection 1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Central Junction Box (CJB) Fuse 5 (10A) ^ Damaged wiring harness ^ Loose or corroded connectors ^ 4-wheel anti-lock brake control module ^ Restraint Control Module (RCM) ^ Generic Electronic Module (GEM)/Central Timer Module (CTM) ^ Powertrain control module (PCM) ^ Parking aid module (PAM) (optional) ^ Remote Anti-theft Personality (RAP) module (optional) ^ Air suspension control module (optional) ^ Passive Anti-theft System (PATS) module ^ Driver Seat Module (DSM) (optional) ^ Electronic Automatic Temperature Control (EATC) module (optional) 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position is in RUN. If the scan tool still does not communicate with the vehicle, go to Pinpoint Test M. See: Pinpoint Tests/Pinpoint Tests/Test M: No Module/Network Communication - No Power to Scan Tool 4. Go to Pinpoint Test PC. See: Pinpoint Tests/Pinpoint Test PC (Precheck) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4095 PC1 Test A: 4WABS Control Module Does Not Respond to Diagnostic Tool Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4096 A1 - A2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4097 A3 - A4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4098 A5 - A6 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4099 B1 - B2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4100 C1 - C2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4101 D1 - D2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4102 D3 - D4 Test E: PCM Does Not Respond to the Diagnostic Tool Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4103 E1 - E2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4104 E3 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4105 E4 - E5 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4106 E6 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4107 F1 - F2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4108 G1 - G2 Test H: DSM No Response Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4109 H1 - H2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4110 H3 - H4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4111 H5 - H6 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4112 I1 - I2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4113 I3 - I4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4114 J1 - J2 Test K: No Module/Network Communication - ISO 9141 Network Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4115 K1 - K2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4116 K3 - K4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4117 K5 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4118 K6 - K7 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4119 K8 K9 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4120 K10 - K11 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4121 K12 - K13 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4122 K14 - K15 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4123 K16 K17 K18 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4124 K19 - K20 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4125 K21 K22 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4126 K23 Test L: No Module/Network Communication - SCP Network L1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4127 L2 - L3 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4128 L4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4129 L5 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4130 L6 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4131 L7 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4132 L8 M1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4133 M2 - M4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4134 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4135 Multiplex Communication Network: Testing and Inspection Module Configuration Inspection and Verification 1. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Damaged wiring harness ^ Loose or corroded connectors ^ 4-wheel Anti-lock Brake Control Module (4WABS) ^ Generic Electronic Module (GEM) 2. If the concern remains after inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch is in RUN position. 3. If the scan tool still does not communicate with the vehicle, refer to Module Communication Network (Information Bus). 4. Refer to the Symptom Chart. See: Diagnosis By Symptom Customer Preference Items NOTE: ^ If using the WDS, select Module Configuration and Programming, then follow the screen prompts. ^ Make sure module is listed as supporting customer preference items and supports the specific item to be configured in the Module Configuration Index. 1. Select Service Bay Functions on the scan tool. 2. Select the module that contains the customer preference item to be programmed. Refer to the Module Configuration Index. See: Scan Tool Testing/Module Configuration Index 3. Select Customer Preference Items on the scan tool. 4. Select Module Option Content. 5. Select the item to be enabled or disabled. 6. Enable or disable the item as necessary to reflect the customer preference. Operational Strategy NOTE: ^ If using the WDS, select Module Configuration and Programming, then follow the screen prompts. ^ Make sure module is listed as supporting tire size and axle ratio configuration in the Module Configuration Index. 1. Select Service Bay Functions on the scan tool. 2. Select the module that contains the Operational Strategy to be programmed. Refer to the Module Configuration Index. See: Scan Tool Testing/Module Configuration Index 3. Select Operational Strategy. 4. Select the vehicle. 5. Select 4x4 for a 4x4 vehicle. Select 4x2 for a 4x2 vehicle. Tire Size and Axle Ratio NOTE: ^ If using the WDS, select Module Configuration and Programming, then follow the screen prompts. ^ Make sure module is listed as supporting tire size and axle ratio configuration in the Module Configuration Index. 1. Select Service Bay Functions on the scan tool. 2. Select the module that contains the Tire Size and Axle Ratio configuration. 3. Select Customer Preference Items. 4. Select Tire Size and Axle Ratio on the scan tool. 5. Select the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4136 6. Enter the correct value for the vehicle according to the chart and finish the routine. If the tire size is not listed on the chart, Go to step 7. 7. Position the vehicle on level ground. Make sure the load weight is within the specific vehicle application. NOTE: The following steps will calculate tire revolutions per mile. This will provide the number that needs to be entered on the scan tool. 8. Inflate the tires to the specified rating. NOTE: Tire pressure must be set when the tires are cold. 9. Measure the rear tire height from the ground to the top of the tire in inches. 10. Divide 20,168 by the tire height measurement. This is the revolutions per mile. 11. Enter the revolutions per mile (rev/mile) on the scan tool and finish the routine. Module Configuration Index NOTE: Do not contact the As-Built Data Center unless the scan tool instructs you to do so. The scan tool will not allow you to use as-built data information unless the scan tool first prompts you for the As-Built Data Center information. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4137 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4138 A1 - A3 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Page 4139 Multiplex Communication Network: Service and Repair Communication Circuit Wiring Repair Heat Gun SPECIAL SERVICE TOOLS 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Strip the wires. 3. Solder the wires 1 Install the heat shrink tube. 2 Twist the wires together. 3 Solder the wires together. NOTE: Use Rosin Core Mildly Activated (RMA) solder, not acid core solder. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Page 4140 4. Bend the wires back in a straight line. NOTE: Wait for the solder to cool before moving the wires. 5. Position the (A) heat shrink tube over the (B) wire repair. ^ Overlap the heat shrink tube on both wires. 6. Use the heat gun to heat the repaired area until adhesive flows out both ends of the heat shrink tube. 7. Reconnect the battery ground cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Tools and Equipment > Tools and Equipment Multiplex Communication Network: Tools and Equipment Recommended Tools Heat Gun Recommended Supplies Raychem SCT(R) heat shrink tubing, Motorcraft part number WT-5627 .................................................................................................. ESB-M99D56-A2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Tools and Equipment > Tools and Equipment > Page 4143 Multiplex Communication Network: Tools and Equipment Diagnostic Special Service Tool(S) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Bolt 25 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 4147 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 4148 Knock Sensor: Description and Operation Knock Sensor Two Types Of Knock Sensor (KS) The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 4149 Knock Sensor: Service and Repair REMOVAL 1. Remove the lower in take manifold. For additional information, refer to Engine. 2. Remove the knock sensor. 1 Remove the bolt. 2 Remove the knock sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4153 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4154 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Locations > Page 4158 Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) Malfunction Indicator Lamp (MIL) Check Engine, Service Engine Soon Or ISO Standard Engine Symbol The Malfunction Indicator Lamp (MIL) (Figure 15) alerts the driver that the Powertrain Control Module (PCM) has detected an OBD II emission-related component or system fault. When this occurs, an OBD II Diagnostic Trouble Code (DTC) will be set. ^ The MIL is located on the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or ISO standard engine symbol (Figure 16). ^ Power is supplied to the MIL whenever the ignition switch is in the RUN or START position. ^ The MIL will remain on in the RUN/START mode as a bulb check during the instrument cluster proveout for approximately 4 seconds. ^ If the MIL remains on after the bulb check: The PCM illuminates the MIL for an emission related concern and a DTC will be present. - The instrument cluster will illuminate the MIL if the PCM does not send a control message to the instrument cluster. - The PCM is operating in the Hardware Limited Operation Strategy (HLOS). - The MIL circuit is shorted to ground. ^ If the MIL remains off (during the bulb check): Bulb is damaged. - MIL circuit is open. ^ To turn off the MIL after a repair, a reset command from the Scan Tool must be sent, or three consecutive drive cycles must be completed without a fault. ^ For any MIL concern, GO to Computers and Control Systems/Testing and Inspection. ^ If the MIL blinks at a steady rate, a severe misfire condition could possibly exist. ^ If the MIL blinks erratically, an intermittent open B+ to the bulb or an intermittent short to ground in the MIL circuit exist. Also, the PCM can reset while cranking if battery voltage is low. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4163 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4164 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4165 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4166 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4167 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4168 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4169 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4170 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4171 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4172 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4173 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4174 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4175 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4176 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4177 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Page 4178 Heated Oxygen Sensor: Specifications Heated Oxygen Sensor 41 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations > Oxygen Sensor Bank Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations > Oxygen Sensor Bank Locations > Page 4181 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated Oxygen 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4184 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4185 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4186 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4187 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4188 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4189 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4190 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4191 Heated Oxygen Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4192 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4193 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4194 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4195 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4196 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4197 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4198 Heated Oxygen Sensor: Connector Views Ford does not provide connector views for this vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 4199 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Heated Oxygen Sensor (HO2S) Monitor Heated Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S) Monitor Heated Oxygen Sensor Monitor The Heated Oxygen Sensor (HO2S) Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration which can affect emissions. The fuel control or upstream HO2S is checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S used for Catalyst Monitor are also monitored for proper output voltage. The following illustration shows that input is required from the Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CHT), Intake Air Temperature (IAT), Mass Air Flow (MAF) and Crankshaft Position (CKP) sensors to activate the HO2S Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. 1. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. The HO2S Monitor evaluates both the upstream (fuel control) and downstream (Catalyst Monitor) HO2S for proper function. 2. Once the HO2S Monitor is enabled, the upstream HO2S signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. A HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the Output State Monitor (OSM) and by measuring the current going through the heater circuit. The HO2S Monitor DTCs can be categorized as follows: The Diagnostic Trouble Code (DTCs) associated with HO2S lack of switching are DTCs P1130, P1131, P1132, P1150, P1151 and P1152. The DTCs associated with HO2S slow response rate are DTCs P0133 and P0153. The DTCs associated with HO2S signal circuit malfunction are DTCs P0131, P0136, P0148, P0151 and P0156. The DTCs associated with a HO2S heater circuit malfunction are DTCs P0135, P0141, P0155 and P0161. The Diagnostic Trouble Code (DTC) associated with the downstream HO2S not running in on-demand is DTC P1127. The DTCs associated with swapped HO2S connectors are DTCs P1128 and P1129. 3. The Malfunction Indicator Lamp (MIL) is activated after a fault is detected on two consecutive drive cycles. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Heated Oxygen Sensor (HO2S) Monitor > Page 4202 Heated Oxygen Sensor: Description and Operation PCM Inputs HEATED OXYGEN SENSOR Heated Oxygen Sensor (HO2S) The Heated Oxygen Sensor (HO2S) (Figure 33) detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop operation. The Vehicle Power (VPWR) circuit supplies voltage to the heater and the PCM will complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater and heater control system are installed on some vehicles. The high power heater reaches closed loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 4203 Heated Oxygen Sensor: Service and Repair EGO Sensor Wrench SPECIAL SERVICE TOOL(S) REMOVAL NOTE: The 5.0L RH is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar. 1. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 2. Remove the bolts and the skid plate. 3. Remove the Three Way Catalytic Converter (TWC). For additional information, refer to Catalytic Converter. 4. Using the special tool, remove the HO2S. NOTE: If necessary, lubricate the HO2S with Penetrating and Lock Lubricant E8AZ-19A501-B or equivalent to assist in removal. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply a light coat of High Temperature Nickel Anti-Sieze Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A to the threads of the HO2S. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 4204 Syncro Positioning Tool Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of 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). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4213 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4214 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4215 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4216 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4217 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of 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). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4223 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4224 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4225 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4226 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4227 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4232 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4233 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4234 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4240 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4241 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4242 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4243 Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR Bolts 8 - 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4244 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4245 Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4246 Tube Mounted Differential Pressure Feedback EGR Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4247 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the differential pressure feedback EGR electrical connector. 3. Disconnect the differential pressure feedback EGR hoses. 4. Remove the bolts and the differential pressure feedback EGR. INSTALLATION 1. Fit the differential pressure feedback EGR and loosely install the bolts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4248 2. Tighten the bolts. 3. Connect the differential pressure feedback EGR hoses. 4. Connect the differential pressure feedback EGR electrical connector. 5. Connect the battery ground cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures Powertrain Control Module: Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 4254 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 4255 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4256 Powertrain Control Module: Specifications PCM Connector 5 - 7 Nm Powertrain Control Module Connector Bolt 7 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4257 Powertrain Control Module: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4258 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4259 Powertrain Control Module: Diagrams Part (1 Of 3) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4260 Part (2 Of 3) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4261 Part (3 Of 3) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > General Description and Operation Powertrain Control Module: Description and Operation General Description and Operation The PCM performs the following functions: ^ accepts input from various engine sensors to compute the required fuel flow rate necessary to maintain a prescribed air/fuel ratio throughout the entire engine operational range. ^ outputs a command to the fuel injectors to meter the appropriate quantity of fuel. ^ determines and compensates for the age of the vehicle and its uniqueness, also automatically senses and compensates for changes in altitude. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > General Description and Operation > Page 4264 Powertrain Control Module: Description and Operation Standard Models (Non BI-Fuel) POWERTRAIN CONTROL MODULE - VEHICLE SPEED OUTPUT (VSO) The PCM-VSO (Powertrain Control Module - Vehicle Speed Output) speed signal subsystem generates vehicle speed information for distribution to the vehicle's electrical/electronic modules and subsystems that require vehicle speed data. This subsystem senses the transmission output shaft speed with a sensor. The data is processed by the PCM, and distributed as a hard-wired signal or as a multiplexed data message. The key features of the PCM-VSO system are to: ^ Infer vehicle movement from the output shaft sensor signal ^ Convert transmission output shaft rotational information to vehicle speed information ^ Compensate for tire size and axle ratio with a programmed calibration variable ^ Utilize a transfer case sensor for four wheel drive applications ^ Distribute vehicle speed information as a multiplexed message and/or an analog signal The signal from a non-contact shaft sensor (Output Shaft Sensor--OSS or Transfer Case Shaft Sensor--TCSS) mounted on the transmission (automatics, manuals, or 4X4 transfer cases) is sensed directly by the PCM. The PCM converts the OSS or TCSS information to 8000 pulses per mile, based on a tire and axle ratio conversion factor. This conversion factor is programmed into the PCM at the time the vehicle is assembled and can be reprogrammed in the field for servicing changes in the tire size and axle ratio. The PCM transmits the computed vehicle speed and distance traveled information to all the vehicle speed signal users on the vehicle. VSO information can be transmitted by a hard-wired interface between the vehicle speed signal user and the PCM, or by Speed and Odometer SCP multiplexed data messages. The VSO hard-wired signal wave form is a DC square wave with a voltage level of 0 to VBAT. Typical output operating range is 2.22Hz per MPH (1.3808 Hz pr 1 Km/h). Multiplexed data for speed and distance data are transmitted as separate SCP messages over the SCP multiplex link. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Flash Electrically Eraseable Programmable Read Only Memory Powertrain Control Module: Service and Repair Flash Electrically Eraseable Programmable Read Only Memory Flash Electrically Eraseable Programmable Read Only Memory - Flash EEPROM Description Flash Electrically Eraseable Programmable Read Only Memory (EEPROM) is contained in an Integrated Circuit (IC) internal to the Powertrain Control Module (PCM). The EEPROM contains the vehicle strategy including calibration information specific to the vehicle and is capable of being reprogrammed or reflashed repeatedly. As part of the calibration there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM as under Programming the VID Block for a Replacement PCM. Failure to perform this procedure may generate fault code: P1639, VID Block not programmed or is corrupt. The VID block in an existing Powertrain Control Module (PCM). can also be tailored to accommodate various hardware changes made to the vehicle since production. Failure to perform this procedure properly may generate fault code: P1635, Tire/Axle Ratio out of Acceptable Range. This is described under Making Changes to the VID Block and also under Making Changes to the PCM Calibration. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the VIN number, octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control and four wheel drive electronic shift on the fly versus manual shift on the fly. Only items applicable to vehicle hardware and supported by the VID block will be displayed on the scan tool. When changing items in the VID block, the strategy will place range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool will display a message indicating the need to flash the PCM again to reset the VID block. Each of the procedures described below use the Worldwide Diagnostic System (WDS). Reprogramming can be performed by a local Ford dealer for any non Ford facility. There are other Enhanced Scan Tools that may have reprogramming capabilities available. Refer to the diagnostic tool manufacturers users manual for details. Programming the VID Block for a Replacement PCM A new PCM will contain the latest strategy and calibration level for a particular vehicle. However, the VID block will be blank and will need programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM and the second is manual data entry into the new PCM. Automatic data transfer will be performed if the old PCM is capable of communicating. This is done by the use of a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can now be downloaded to the new PCM after it has been replaced. Manual data entry must be performed if the old module is damaged and is incapable of communicating. Remove and replace the old PCM. You may be instructed to contact the "AS BUILT" data center for the information needed to manually update the VID block with the scan tool. Contact the center ONLY if the old PCM cannot be used or the data is corrupt. For Ford L-M technician's, contact your National Hotline for "AS Built" data. Non Ford technicians, use the Fed World website at "fedworld.gov". Select Auto Service Information and search for "Calibrations" or "Vehicle Calibrations" then specify vehicle manufacturer, model name and model year as required. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate vehicle hardware. Refer to PCM/Module Reprogramming on the Scan Tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM will need to be completely reprogrammed. This is due to changes made to the strategy or calibration after production or the need to reset the VID block because it has reached its limit. Refer to PCM/Module Reprogramming on the Scan Tool. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Flash Electrically Eraseable Programmable Read Only Memory > Page 4267 Powertrain Control Module: Service and Repair Removal and Installation REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Powertrain Control Module (PCM) electrical connector. 3. Remove the nuts and the PCM cover. 4. Remove the PCM. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4271 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4272 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Description and Operation Absolute Pressure Sensor: Description and Operation THERMAL MANIFOLD ABSOLUTE PRESSURE SENSOR Thermal Manifold Absolute Pressure (TMAP) Sensor The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 41) consists of a Manifold Absolute Pressure (MAP) sensor and an integrated thermistor. The thermistor part of the sensor is currently not being used. The MAP part of the sensor measures intake manifold air absolute pressure. The PCM uses information from the MAP sensor, Throttle Position (TP) sensor, Mass Air Flow (MAF) sensor, Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CKP) sensor and Crankshaft Position (CKP) sensor to determine how much exhaust gas is introduced into the intake manifold. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications Mass Air Flow Sensor: Specifications Mass Air Flow Sensor Nuts And Bolts 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4280 Mass Air Flow Sensor: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4281 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4282 Mass Air Flow Sensor: Description and Operation MASS AIR FLOW SENSOR Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4283 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Loosen the air cleaner outlet tube clamp and position aside. 4. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor, Stud Bolt 19 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 4287 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 4288 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 4289 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the CMP sensor electrical connector. 2 Remove the CMP sensor stud bolt. 3 Remove the camshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams > Page 4293 Clutch Switch: Description and Operation CLUTCH PEDAL POSITION SWITCH Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch (Figure 24) is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference Vehicle Reference Voltage (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor 15 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 4297 Coolant Temperature Sensor/Switch (For Computer): Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 4298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 4299 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL 1. Remove the thermostat and housing. For additional information, refer to Cooling System. 2. Disconnect the battery ground cable. For additional information, refer to Battery. 3. Remove the Engine Coolant Temperature (ECT) sensor. 1 Disconnect the connector. 2 Remove the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolts 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 4303 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Electronic Engine Controls Crankshaft Position Sensor: Description and Operation Electronic Engine Controls The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Electronic Engine Controls > Page 4306 Crankshaft Position Sensor: Description and Operation Standard Models (Non BI-Fuel) CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference (Figure 25). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Page 4307 Crankshaft Position Sensor: Service and Repair REMOVAL NOTE: The 5.0L is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Crankshaft Position (CKP) sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ 4.0L SOHC and 4.0L (push rod) CKP sensors need to be touching the damper. The CKP sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure sensor wiring is routed away from the battery cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor CYLINDER HEAD TEMPERATURE SENSOR Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by allowing air cooling of the engine and limp home capability. For additional information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy details. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor > Page 4312 Engine Temperature Sensor: Description and Operation Engine Coolant Temperature (ECT) Sensor ENGINE COOLANT TEMPERATURE (ECT) SENSOR Engine Coolant Temperature (ECT) Sensor The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. The ECT sensor is similar in construction to the IAT sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation The fuel sending unit is a variable resistor made up of a ceramic substrate. It is controlled by the action of a float arm. When the fuel level is low, resistance in the unit is low. When the fuel level is high, the resistance is high. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 4319 Fuel Tank Pressure Sensor: Service Precautions CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 4320 Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure Sensor Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The Fuel Tank Pressure (FTP) sensor (Figure 97) or inline Fuel Tank Pressure (FTP) sensor (Figure 98) is used to measure the fuel tank pressure during the EVAP monitor test on vehicles equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank pressure by forcing the system to purge. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 4321 Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Remove the fuel tank. For additional information, refer to Fuel Delivery and Air Induction. 2. Remove the fuel tank pressure sensor. 1 Disconnect the electrical connector. 2 Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the fuel tank. CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. INSTALLATION 1. To install, reverse removal procedure. ^ Leak test the evaporative emission system. For additional information, refer to Evaporative Emission System Leak Test System. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emissions repair verification drive cycle. For additional information, refer to Evaporative Emission Repair Verification Drive Cycle. See: Emission Control Systems/Evaporative Emissions System/Service and Repair Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation Intake Air Temperature Sensor: Description and Operation INTAKE AIR TEMPERATURE SENSOR Intake Air Temperature (IAT) Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire Terminals The Intake Air Temperature (IAT) sensors (Figure 34) and integrated Mass Air Flow (MAF) type (Figure 37), are thermistor devices in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Page 4325 Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel spark and MAF. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Supercharged 5.4L Lightning vehicles use (2) AT sensors. Both sensors operate as above. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor Second Intake Air Temperature (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Bolt 25 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 4329 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 4330 Knock Sensor: Description and Operation Knock Sensor Two Types Of Knock Sensor (KS) The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 4331 Knock Sensor: Service and Repair REMOVAL 1. Remove the lower in take manifold. For additional information, refer to Engine. 2. Remove the knock sensor. 1 Remove the bolt. 2 Remove the knock sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4336 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4337 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4338 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4339 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4340 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4341 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4342 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4343 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4344 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4345 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4346 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4347 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4348 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4349 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4350 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Page 4351 Heated Oxygen Sensor: Specifications Heated Oxygen Sensor 41 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations > Oxygen Sensor Bank Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations > Oxygen Sensor Bank Locations > Page 4354 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated Oxygen 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4357 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4358 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4359 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4360 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4361 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4362 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4363 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4364 Heated Oxygen Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4365 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4366 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4367 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4368 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4369 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4370 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4371 Heated Oxygen Sensor: Connector Views Ford does not provide connector views for this vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 4372 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Heated Oxygen Sensor (HO2S) Monitor Heated Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S) Monitor Heated Oxygen Sensor Monitor The Heated Oxygen Sensor (HO2S) Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration which can affect emissions. The fuel control or upstream HO2S is checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S used for Catalyst Monitor are also monitored for proper output voltage. The following illustration shows that input is required from the Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CHT), Intake Air Temperature (IAT), Mass Air Flow (MAF) and Crankshaft Position (CKP) sensors to activate the HO2S Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. 1. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. The HO2S Monitor evaluates both the upstream (fuel control) and downstream (Catalyst Monitor) HO2S for proper function. 2. Once the HO2S Monitor is enabled, the upstream HO2S signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. A HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the Output State Monitor (OSM) and by measuring the current going through the heater circuit. The HO2S Monitor DTCs can be categorized as follows: The Diagnostic Trouble Code (DTCs) associated with HO2S lack of switching are DTCs P1130, P1131, P1132, P1150, P1151 and P1152. The DTCs associated with HO2S slow response rate are DTCs P0133 and P0153. The DTCs associated with HO2S signal circuit malfunction are DTCs P0131, P0136, P0148, P0151 and P0156. The DTCs associated with a HO2S heater circuit malfunction are DTCs P0135, P0141, P0155 and P0161. The Diagnostic Trouble Code (DTC) associated with the downstream HO2S not running in on-demand is DTC P1127. The DTCs associated with swapped HO2S connectors are DTCs P1128 and P1129. 3. The Malfunction Indicator Lamp (MIL) is activated after a fault is detected on two consecutive drive cycles. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Heated Oxygen Sensor (HO2S) Monitor > Page 4375 Heated Oxygen Sensor: Description and Operation PCM Inputs HEATED OXYGEN SENSOR Heated Oxygen Sensor (HO2S) The Heated Oxygen Sensor (HO2S) (Figure 33) detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop operation. The Vehicle Power (VPWR) circuit supplies voltage to the heater and the PCM will complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater and heater control system are installed on some vehicles. The high power heater reaches closed loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 4376 Heated Oxygen Sensor: Service and Repair EGO Sensor Wrench SPECIAL SERVICE TOOL(S) REMOVAL NOTE: The 5.0L RH is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar. 1. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 2. Remove the bolts and the skid plate. 3. Remove the Three Way Catalytic Converter (TWC). For additional information, refer to Catalytic Converter. 4. Using the special tool, remove the HO2S. NOTE: If necessary, lubricate the HO2S with Penetrating and Lock Lubricant E8AZ-19A501-B or equivalent to assist in removal. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply a light coat of High Temperature Nickel Anti-Sieze Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A to the threads of the HO2S. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 4377 Syncro Positioning Tool Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of 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). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4386 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4387 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4388 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4389 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4390 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of 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). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4396 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4397 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4398 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4399 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4400 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4405 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4406 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4407 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 4413 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 4414 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 4415 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 4416 Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR Bolts 8 - 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 4417 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 4418 Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 4419 Tube Mounted Differential Pressure Feedback EGR Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 4420 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the differential pressure feedback EGR electrical connector. 3. Disconnect the differential pressure feedback EGR hoses. 4. Remove the bolts and the differential pressure feedback EGR. INSTALLATION 1. Fit the differential pressure feedback EGR and loosely install the bolts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 4421 2. Tighten the bolts. 3. Connect the differential pressure feedback EGR hoses. 4. Connect the differential pressure feedback EGR electrical connector. 5. Connect the battery ground cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4425 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs Throttle Position Sensor: Description and Operation PCM Inputs THROTTLE POSITION SENSOR Typical Throttle Position (TP) Sensor The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs > Page 4428 Throttle Position Sensor: Description and Operation Intake Air Systems THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the On-Board Diagnostic (OBD) II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page 4429 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the accelerator control snow shield. 3. Remove the Throttle Position (TP) sensor. 1 Disconnect the TP sensor electrical connector. 2 Remove the sensor. NOTE: The 4.0L (SOHC) is shown, the 4.0L push rod is similar. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital transmission range (TR) sensor screws 71 - 97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4433 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4434 Digital Transmission Range Sensor: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4435 Digital Transmission Range Sensor: Service and Repair Special Tools Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the shift cable. 1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the bracket. 4. Disconnect the digital transmission range (TR) sensor electrical connector. 5. Remove the manual control outer lever nut and manual control outer lever. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4436 6. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor. 1. Position the digital TR sensor. 2. Loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Note: The manual lever must he in the neutral position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever. 1. Install the manual control outer lever. 2. Install the manual control outer lever nut. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4437 4. Connect the digital transmission range (TR) sensor electrical connector. 5. Connect the shift cable. 1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. Connect the battery ground cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Vehicle Speed Sensor Bolt 98 - 115 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4443 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4444 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4445 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4446 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4447 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4448 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4449 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4450 Vehicle Speed Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4451 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4452 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4453 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4454 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4455 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4456 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4457 Diagram 64-1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 4458 Vehicle Speed Sensor: Description and Operation VEHICLE SPEED SENSOR Typical Vehicle Speed Sensor (VSS) The Vehicle Speed Sensor (VSS) (Figure 45) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling and torque converter clutch scheduling. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4462 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs Throttle Position Sensor: Description and Operation PCM Inputs THROTTLE POSITION SENSOR Typical Throttle Position (TP) Sensor The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs > Page 4465 Throttle Position Sensor: Description and Operation Intake Air Systems THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the On-Board Diagnostic (OBD) II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page 4466 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the accelerator control snow shield. 3. Remove the Throttle Position (TP) sensor. 1 Disconnect the TP sensor electrical connector. 2 Remove the sensor. NOTE: The 4.0L (SOHC) is shown, the 4.0L push rod is similar. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital transmission range (TR) sensor screws 71 - 97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4470 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4471 Digital Transmission Range Sensor: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4472 Digital Transmission Range Sensor: Service and Repair Special Tools Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the shift cable. 1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the bracket. 4. Disconnect the digital transmission range (TR) sensor electrical connector. 5. Remove the manual control outer lever nut and manual control outer lever. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4473 6. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor. 1. Position the digital TR sensor. 2. Loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Note: The manual lever must he in the neutral position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever. 1. Install the manual control outer lever. 2. Install the manual control outer lever nut. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4474 4. Connect the digital transmission range (TR) sensor electrical connector. 5. Connect the shift cable. 1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. Connect the battery ground cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System Variable Valve Timing Actuator: Description and Operation Variable Cam Timing System Variable Cam Timing System Overview The Variable Cam Timing System allows the exhaust cam to advance and retard at varying engine speeds. The purpose of this is to reduce exhaust emissions and increase fuel economy. As the exhaust cam retards in relation to the crankshaft position, residual exhaust gases are left in the combustion chamber. The residual gases cool the combustion chamber and are inert when mixed with the incoming fresh charge of fuel and air. This results in better fuel economy and lower Nitrogen Oxides (NOx) and Hydrocarbons (HG) the engine produces. The Exhaust Gas Recalculation System (EGR) is unnecessary on the 2.0L (4V) engine due to this feature. Variable Cam Timing The Variable Cam Timing (VCT) system consists of the control solenoid, five-tooth pulse ring (4+1) on exhaust camshaft, Intake Air Temperature (IAT) sensor, Engine Coolant Temperature (ECT) sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor, Crankshaft Position (CKP) sensor, Powertrain Control Module (PCM) (Figure 129). 1. The Powertrain Control Module (PCM) receives input signals from the Intake Air Temperature (IAT) sensor, Engine Coolant Temperature (ECT) sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor and Crankshaft Position (CKP) sensor for determining the operating conditions of the engine. 2. The Variable Cam Timing (VCT) system is enabled by the PCM when the proper conditions are met. The PCM disables the VCT system if a fault is detected. 3. The PCM calculates relative cam position using the CMP sensor and data from the (4+1) pulse ring mounted on the exhaust camshaft. Relative cam position is calculated by measuring the time between the rising edge of Profile Ignition Pickup (PIP) and the falling edge of Variable Cam Timing (VCT) pulse. 4. The PCM continually calculates a cam position error value based on the difference between the desired and actual position and a duty cycle is commanded for the VCT solenoid valve. Engine oil is allowed to flow to the VCT unit. 5. Oil flows to either side of the piston chamber changing a linear motion from the piston to a rotation motion from the helical mechanism in the VCT unit. During closed loop the PCM outputs a revised duty cycle to the VCT solenoid valve to correct for cam position error. Variable Cam Timing System HARDWARE Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 4479 Variable Cam Timing (VCT) Solenoid Valve Variable Cam Timing (VCT) Solenoid Valve The VCT solenoid valve (Figure 130) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam timing. Variable Cam Timing Unit Assembly Variable Cam Timing (VCT) Unit Assembly The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the piston to move linearly along the axis of the camshaft. This linear motion is translated into rotational camshaft motion through the helical spline coupling. A spring installed Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 4480 in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up to 30 degrees. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 4481 Variable Valve Timing Actuator: Description and Operation Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing (VCT) Unit Assembly Variable Cam Timing Unit Assembly The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the piston to move linearly along the axis of the camshaft. This linear motion is translated into rotational camshaft motion through the helical spline coupling. A spring installed in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up to 30 degrees. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Description and Operation Variable Valve Timing Solenoid: Description and Operation VARIABLE CAM TIMING (VCT) SOLENOID VALVE Variable Cam Timing (VCT) Solenoid Valve The Variable Cam Timing (VCT) solenoid valve (Figure 130) is an integral part of the VCT system. The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam timing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor Bolt 98 - 115 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4490 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4491 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4492 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4493 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4494 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4495 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4496 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4497 Vehicle Speed Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4498 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4499 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4500 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4501 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4502 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4503 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4504 Diagram 64-1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 4505 Vehicle Speed Sensor: Description and Operation VEHICLE SPEED SENSOR Typical Vehicle Speed Sensor (VSS) The Vehicle Speed Sensor (VSS) (Figure 45) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling and torque converter clutch scheduling. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Solenoid > Component Information > Description and Operation Air Diverter Solenoid: Description and Operation AIR BYPASS SOLENOID Secondary Air Injection Bypass Solenoid The secondary air injection bypass (AIR bypass) solenoid (Figure 122) is used by the PCM to control vacuum to the secondary air injection diverter (AIR diverter) valve. The AIR bypass solenoid is a normally closed solenoid. The AIR bypass solenoid also has a filtered vent feature to permit vacuum release. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve > Component Information > Description and Operation Air Diverter Valve: Description and Operation AIR DIVERTER VALVE Air Injection Diverter (AIR Diverter) Valve The secondary air injection diverter (AIR diverter) valve (Figure 123) is used with the electric AIR pump to provide on/off control of air to the exhaust manifold and catalytic converter. When the electric AIR pump is on and vacuum is supplied to the AIR diverter valve, air passes the integral check valve disk. When the electric AIR pump is off, and vacuum is removed from the AIR diverter valve, the integral check valve disk is held on the seat and stops air from being drawn into the exhaust system and prevents the back flow of the exhaust into the Secondary Air Injection System. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump > Component Information > Description and Operation Air Injection Pump: Description and Operation ELECTRIC AIR PUMP Electric Air Pump The electric AIR pump (Figure 121) provides pressurized air to the Secondary Air Injection system. The electric AIR pump functions independently of rpm and is controlled by the PCM. The electric AIR pump is only used for short periods of time. Delivery of air is dependent on the amount of system backpressure and system voltage. The inlet system of the AIR pump incorporates a non-serviceable filter and splash cap which helps to guard against dirt and water. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump Relay > Component Information > Description and Operation Air Injection Pump Relay: Description and Operation SOLID STATE RELAY Solid State Relay The solid state relay (Figure 124) switches the high current required for operation of the electric AIR pump. Input control to the solid state relay comes from the Powertrain Control Module (PCM). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Vacuum Check Valve, AIR > Component Information > Description and Operation Vacuum Check Valve: Description and Operation VACUUM CHECK VALVES Vacuum Check Valve A vacuum check valve (Figure 125) blocks air flow in one direction. It allows free air flow in the other direction. The check side of this valve will hold the highest vacuum registered on the vacuum side. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4527 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4528 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4529 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4530 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4531 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4532 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4533 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4534 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4535 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4536 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4537 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4538 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4539 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4540 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4541 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4542 Catalytic Converter: Specifications Three-Way Catalytic Converter Bolts and Nut 25 - 34 ft.lb Three-Way Catalytic Converter-to-Exhaust Manifold Bolts (4.0L SOHC) 27 - 37 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions Catalytic Converter: Description and Operation Acronyms and Definitions 2V - L ACRONYMS AND DEFINITIONS NOTE: This Acronyms and Definitions listing contains technical terms applicable to Ford Motor Company products. It is not intended to be an all-inclusive dictionary of components and their functions. If a detailed description of a particular system or component is desired, refer to the applicable Vehicle System for the specific vehicle being serviced. 2V: Two Valve engine configuration. 4V: Four Valve engine configuration. ABS: Anti-lock Brake System. A/C: Air Conditioning. A vehicle accessory system that modifies the passenger compartment air by cooling and dehydrating the air. ACC: Air Conditioning Clutch. Indicates status of the A/C clutch. ACCS: Air Conditioning Cycling Switch. Indicates status of the A/C cycling switch. ACD: Air Conditioning Demand. A signal input to the PCM from the Air Conditioning control panel. ACP: Air Conditioning Head Pressure or A/C cycling switch input state. ACPSW: Air Conditioning Pressure Switch. ACPV: Air Conditioning Head Pressure Volts. A voltage input to the Powertrain Control Module (PCM) from the ACP switch or sensor. ACR: Air Conditioning Relay. Commanded output controlled by the PCM and acts as an A/C cutout control during heavy acceleration. A/D: Analog-to-Digital. Analog-to-Digital signal conversion. ADC: See ATDC. AFCM: Alternative Fuel Control Module. AIR: Secondary Air Injection. AIRB: Secondary Air Injection Bypass. Air Diverter: Air Diverter Valve. Part of the EAIR system. Diverts fresh air to the exhaust system when the electric air pump is commanded on. AIR EVAL: Air System Evaluated. Displays a YES or NO status indicating whether the Air System has been evaluated for OBD (On-Board Diagnostic) II purposes. Air/Fuel Ratio: Air to fuel mixture ratio. An air/fuel mixture that is 14.7:1 is also called stoichiometry. AIRM: Secondary AIR pump monitor. Ambient Air Temperature: Temperature of the air surrounding an object. Analog (Electrical/Electronic): An electrical signal that can obtain any value within the voltage limits of the signal. ARB: Air Resource Board. ARPMIDES: Ancillary RPM Desired. RPM required to maintain the vehicle speed commanded by Speed Control Command Switch (SCCS) inputs. ASCII: American Standard Code for Information Interchange. ATDC: After Top Dead Center. The location of the piston after it has reached the top of its stroke. Measured in degrees of crankshaft rotation. AVOM: Analog Volt-Ohm Multimeter. Readings are indicated by a sweep hand on a printed scale, rather than a digital display. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4545 AWD: All-Wheel Drive. BARO: Barometric Pressure. Base Idle: Idle rpm determined by the throttle lever hardset on the throttle body with the IAC solenoid disconnected. Base Timing: Spark advance in degrees before top dead center of the base engine without any control from the PCM or ICM. Battery Positive Voltage (B+): The positive (+) voltage from the battery or any circuit connected directly to the battery. Compare "Vehicle Power (VPWR)." BAT TEMP: Battery Temperature. BJB: Battery Junction Box. BOB: Breakout Box. A test device which connects in series to the PCM and PCM harness. BPA: Brake Pedal Applied switch. Typically located on the braking system master cylinder. Can be hydraulic or electric. BPP: Brake Pedal Position. Indicates the position of the brake pedal, based on input from the Brake Pedal Position (BPP) switch. BRAKE LMP or BRKL: Brake Warning Lamp Status. Activates the Brake Warning Lamp by applying voltage to the control line. BTDC: Before Top Dead Center. The location of the piston before it has reached the top of its stroke. Measured in degrees of crankshaft rotation. Bus + or Bus -: Multiplex circuits that carry Standard Corporate Protocol (SCP) data from module to module and to the DLC. CAC: Charge Air Cooler. Formerly known as Intercooler. A device which lowers the temperature of pressurized intake air. CAFE: Corporate Average Fuel Economy. A set of federal requirements and regulations which govern fuel economy standards. CANVNT: Canister Vent Solenoid. Catalyst: Catalytic converter. An in-line exhaust system device used to reduce the level of engine exhaust emissions. CAT EVAL: Catalyst System Evaluated. This item indicates YES when the Catalyst Efficiency Monitor has successfully completed. CCM: Comprehensive Component Monitor. CCRM: Constant Control Relay Module. A relay module that provides ON-OFF control of various EEC components. CD A through J: Coil Driver 1 through 10. Centralized Testing Facility: State government operation. Provides Inspection/Maintenance (IM) and safety inspections. CGND or CSE GND: Case Ground. Provides a ground source for the PCM or ECU case. CHT: Cylinder Head Temperature. Units are displayed in either degrees Fahrenheit or Centigrade. CHTIL: Cylinder Head Temperature Indicator Lamp. CHTV: Cylinder Head Temperature Voltage. The actual voltage drop across the CHT sensor thermistor. CID: Cylinder Identification. PCM input signal from Camshaft Position Sensor. CKP: Crankshaft Position. Senses the position of the crankshaft. CKP+, CKP-: CKP+ is the Crankshaft Position (CKP) sensor signal wire. CKP - is the signal return. CL: Closed Loop. An operating condition or mode which enables operation based on sensor feedback. CMP: Camshaft Position. Indicates camshaft position. CMPFM: Camshaft Position Failure Mode. Indicates when the PCM identifies a CID/CMP fault. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4546 CMS: Catalyst Monitor Sensor. Downstream H025. CMVSS: Canadian Motor Vehicle Safety Standards. CNG: Compressed Natural Gas. CO: Carbon Monoxide. A colorless, odorless and toxic gas that is a component of auto exhaust emissions. CO(2): Carbon Dioxide. A colorless, odorless gas that is a normal by-product of the combustion of fuel. Coil: A device consisting of windings around an iron core. In a spark ignition system, designed to increase voltage. Cold Soak: Time given to a vehicle to sit at a low temperature (typically below 68°F / 20°C) until the temperature of external and internal components stabilize. CONT: Continuous Memory. The portion of KAM (Keep Alive Memory) used to store DTCs generated during Continuous Memory Self-Test. Continuous Memory Self- Test: A continuous test of the EEC system conducted by the PCM whenever the vehicle is operating. CPP: Clutch Pedal Position. Indicates clutch pedal position. CPP Switch: Clutch Pedal Position Switch. Located on the clutch pedal and detects when the clutch pedal is depressed. CQIS: Common Quality Indicator System. CSE GND: Case Ground. CT: Closed Throttle Mode. A mode when the PCM varies the pulse width of the fuel injectors to obtain the air/fuel mixture appropriate for closed throttle operation. CTO: Clean Tach Output. Signal used to drive the instrument panel tachometer. Data Communications Link: A communication path between various in-vehicle electronic modules. Accessed by scan tools through the Data Link Connector (DLC). DC: 1. Direct Current. Electric current flowing in one direction. 2. Duty Cycle. The voltage measurement of ON time versus the full cycle period, expressed in percent. DCL: Data Communication Link. DI: Distributor Ignition. A system in which the ignition coil secondary circuit is sequenced by a distributor. Digital: Controls process information by switching the current or voltage ON and OFF. DLC: Data Link Connector. J1962 connector providing access to vehicle diagnostic information. DOHC: Dual Overhead Cam. An engine configuration that uses two camshafts positioned above the valves. DOL: Data Output Line. A circuit that sends certain information from the PCM to the instrument cluster. DPFEGR: Differential Pressure Feedback Exhaust Gas Recirculation. System that uses a pressure transducer to control the operation of the Exhaust Gas Recirculation (EGR) Vacuum Regulator Valve. DRI: Deposit Resistant Injector. A fuel injector designed to prevent build-up of carbon and other unwanted deposits. DRL: Daytime Running Lamps. A system that keeps the vehicle running lamps on at all times while the vehicle is operating. DTM: Diagnostic Test Mode. A level of capability in an On-Board Diagnostic (OBD) system. DTC: Diagnostic Trouble Code. An alpha/numeric identifier for a fault condition identified by the On-Board Diagnostic System. DVOM: Digital Volt-Ohm Meter. E-85: Fuel containing 85% ethanol alcohol. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4547 EAIR: Electric Secondary Air Injection. A pump-driven system for providing secondary air using an electric air pump. EAIRM: Electric Secondary Air Pump circuit Monitor. ECT: Engine Coolant Temperature. Displayed in either Fahrenheit or Centigrade. ECTV: Engine Coolant Temperature Voltage. The actual voltage drop across the ECT sensor thermistor. ECU: Electronic Control Unit. A module that handles the control strategy and monitors system inputs or outputs. EEC: Electronic Engine Control system. EEC-V: Fifth generation EEC system. EFT: Engine Fuel Temperature. EFTA: Bank 1 input. EFTA is displayed in either Fahrenheit or Centigrade. EFTAV: Voltage drop across the EFTA (Bank 1) sensor thermistor. EFTB: Bank 2 input. EFTB is displayed in either Fahrenheit or Centigrade. EFTBV: Voltage drop across the EFTB (Bank 2) sensor thermistor. EGR: Exhaust Gas Recirculation. A process in which a small amount of exhaust gas is routed into the combustion chamber. EGR EVAL: Exhaust Gas Recirculation System Evaluated. EGR EVAL will display YES when the monitor is complete. EGRMDSD: Electric Exhaust Gas Recirculation Motor Desired position. The PID name used to operate the Electric Exhaust Gas Recirculation (EEGR) valve with scan tool's output state control. EGRS: EGR Shutoff. A normally closed solenoid that applies vacuum to the EGR valve when energized by the PCM. EGRT: Exhaust Gas Recirculation Valve Temperature Sensor. A temperature sensor that is threaded into the bottom of the intake plenum. EGR Vacuum Regulator: Controls vacuum to the EGR valve by a duty cycle signal from the PCM. EGRVR: Exhaust Gas Recirculation Vacuum Regulator. Solenoid which varies the vacuum to the EGR valve by varying the duty cycle to the regulator. EGRVRA: Exhaust Gas Recirculation Vacuum Regulator Actual (volt). The actual state of the commanded output. EGRVRF: Exhaust Gas Recirculation Vacuum Regulator Fault. Represents whether a fault exists in the EGRV circuit. EI: Integrated Electronic Ignition. An Electronic Ignition system that has the Ignition Control Module (ICM) integrated into the PCM. EI-HDR: Electronic Ignition, High Data Rate. Formerly known as Electronic Distributorless Ignition System. EI-LDR: Electronic Ignition, Low Data Rate. Formerly known as Distributorless Ignition System. EMI: Electromagnetic Interference. Usually caused by ignition voltage spikes, solenoids, relay operation or noisy generator contacts. EOL: End Of Line. A system designed specifically for use at assembly plants to make sure all new vehicles perform to design specifications. EPA: Environmental Protection Agency (U.S. Government). EPROM: Erasable Programmable Read-Only Memory. An electronic component in the PCM that requires the electronic storage of information. ESOF: Electronic Shift-on-the-Fly. EVAP: Evaporative Emissions. A system to prevent fuel vapor from escaping into the atmosphere. EVAPCP: Evaporative Canister Purge Solenoid. Controls a solenoid which allows venting of the evaporative purge canister. EVAPCPF: Evaporative Canister Purge Solenoid Fault. Identifies whether an electrical fault exists for the current commanded state. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4548 EVAPCV: Evaporative Canister Vent Solenoid. Controls a solenoid which seals the EVAP system canister from atmospheric pressure during the EVAP OBD II Monitor test. Evaporative Emissions Canister: An evaporative emission canister, containing activated charcoal which absorbs and holds fuel vapors. EVAPPDC: Evaporative Canister Purge Duty Cycle. The duty cycle commanded to the Evap Canister Purge Solenoid by the PCM. EVO: Electronic Variable Orifice. EWP: Electric Water Pump. Exciter Ring: A toothed or notched iron or steel disk, which is the moveable part of a wheel speed sensor. FAN: Fan Speed. Used in conjunction with vehicles having multiple fan speed control. Displays OFF, LOW, or HIGH status. FC: Fan Control. FCS: Fuel Control Solenoid. FCIL: Fuel Cap Off Indicator Lamp. Indicates that the fuel filler cap was not properly installed. FEAD: Front End Accessory Drive. FEPS: Flash Electrically Erasable Programmable Read Only Memory (EEPROM) Programming Signal. 18 volt DC signal sent by the scan tool to initiate PCM reprogramming. FF: 1. Flexible Fuel. A system capable of using a variety of fuels for vehicle operation. 2. A PID that displays the % alcohol content in fuel. FFLRN: Flex Fuel Learned. Displays when the PCM's Flex Fuel strategy has completed calculating the inferred alcohol content of fuel. FFFM: Flexible Fuel Failure Mode. Indicates whether the current Flex Fuel Sensor reading (FF) is reliable or not. Displays a YES or NO. FFTEMP: Flexible Fuel Sensor - Temperature. Alcohol concentration derived from the signal pulse width. FFV: Flexible Fuel Vehicle. FIFO: First In First Out. FILO: First In Last Out. FIM: Fuel Indicator Module. FLI: Fuel Level Input. Used by the Evap monitor to calculate fuel tank vapor volume. Displayed as a percentage. FLIV: Fuel Level Input Voltage. FMEM: Failure Mode Effects Management. Operating strategy that maintains limited vehicle function in the event of a PCM or EEC component failure. FP:1. Fuel Pump. Indicates whether the pump has been commanded ON or OFF by the PCM. 2. Fuel Pump (Modulated). Fuel pump duty cycle percentage. FPDM: Fuel Pump Driver Module. A module that controls the electric fuel pump. FPF: Fuel Pump Fault. Identifies whether a fault exists in the FP circuit. FPM: Fuel Pump Monitor. Monitors the Fuel Pump I circuits for faults. Freeze Frame: A block of memory containing the vehicle operating conditions at a specific time. FRP: Fuel Rail Pressure. Based on FRP V. FRP V: Fuel Rail Pressure Voltage. A voltage input to the PCM from the Fuel Rail Pressure Sensor. FSC: Fail-Safe Cooling. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4549 FSV: Fuel Shut-off Valve. A component of Natural Gas Vehicles. This valve either allows or prevents Natural Gas flow to the fuel rail. FSVF: Fuel Shut-Off Valve Fault. Indicates if there is a fault in the FSV circuit. Displayed as YES or NO. FSVM: Fuel Shut-off Valve Monitor. Monitors operation of the Fuel Shut-Off Valve / circuit. FTP: Fuel Tank Pressure. Displayed as inches of water, kPa, or volts. FTP V: Fuel Tank Pressure Voltage. From the FTP transducer. FUEL PR: Fuel Pressure. Measurement of the force of the fuel delivered via the fuel pump. FUELPW: Fuel Pulse Width. Displays the commanded pulse width at time of last data update. FUELPW1: Fuel Injector Pulse Width #1. Corresponds to injectors normally affected by O2S1 (HEGO1). FUELPW2: Fuel Injector Pulse Width #2. Corresponds to injectors normally affected by O2S2 (HEGO2). FUELSYS: Fuel System Status (OPEN/CLOSED Loop). Formerly known as LOOP. Fuel Tank Vapor Valve: A valve mounted in the top of the fuel tank that vents excess vapor and pressure from the fuel tank into the Evaporative Emission Control System. FWD: Front Wheel Drive. GEM: Generic Electronic Module. GEN: Generator. GENF: Generator Output Fault. GENFDC: Generator Field Control Output. GFS: Generator field signal monitor. GND: Ground. GPM: Grams Per Mile. Also known as Gallons Per Minute. GPS: Global Positioning Satellite. Green State Vehicle: Formally known as California Emissions. A vehicle that is equipped with California on-board diagnostics. GSS: Gear Select Solenoid. GVW: Gross Vehicle Weight. Hall Effect: A process where current is passed through a small slice of semi-conductor material and a magnetic field to produce a small voltage in the semi-conductor. Hard Fault: A fault currently present in the system. HC: 1. Hydrocarbon. A by-product of combustion and a component of auto exhaust emissions. 2. High Compression. HCF: Hydraulic Cooling Fan. HCFD: Hydraulic Cooling Fan Drive. HFC: Hydraulic Cooling Fan. HFCF: High Fan Control Fault. Identifies if there is a fault in the HFC circuit. HFP: High Fuel Pump. HLOS: Hardware Limited Operating Strategy. A mode of operation where the PCM replaces output commands with fixed values in response to internal Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4550 PCM malfunctions. HO: High Output. HO2S: Heated Oxygen Sensor. Formerly known as Heated Exhaust Gas Oxygen (HEGO) Sensor. Provides information on rich or lean exhaust conditions to the PCM. Hot Soak: Period of time after an engine operates where localized combustion heat dissipates throughout the engine. HTR, HTR11, HTR12, HTR21 H1R22, HTRX1, HTRX2: HO2S Heater. Heater element for the HO2S sensor. Hydrogen: Chemical symbol H. Highly flammable gas. Hz: Hertz. Cycles per second. IAC: Idle Air Control. Electrical control of throttle bypass air. IAT: Intake Air Temperature. IATV: Intake Air Temperature Voltage. Actual voltage drop across the IAT sensor. IAT2: Intake Air Temperature 2. Displayed in either Fahrenheit or Centigrade. Used on supercharged vehicles. IAT2V: Intake Air Temperature 2 Voltage. Actual voltage drop across the IATV2 sensor. IC: Integrated Circuit. A small Semi-Conductor device capable of doing many separate circuit functions. ICM: Ignition Control Module. The module that controls the ignition system. IFDM: Integrated Fuel Delivery Module. IFS: Inertia Fuel Shutoff. IGN GND: Ignition Ground. Ignition: System used to provide high voltage spark for internal combustion engines. IGNKEY(IGKY): Ignition Key status. IGNSW (IGSW): Ignition Switch Position. IMRC: Intake Manifold Runner Control. Controls airflow through the high-speed runners in the intake manifold. IMRCM: Intake Manifold Runner Control Monitor. Monitors the IMRC / circuits for faults. IMTV: Intake Manifold Tuning Valve. Controls airflow through runners in a split intake manifold. INJ1, INJ2, INJ3, INJ4, INJ5, INJ6, INJ7, INJ8, INJ9, INJ1O: lnjector number or its signal output from the PCM. Injector: A device for delivering metered pressurized fuel to the intake system or the cylinders. Intake Air: Air drawn through a filter and distributed to each cylinder for use in combustion. Intercooler: See CAC. IPATS: Integrated Passive Anti-Theft System. ISO: international Standards Organization. KAM: Keep Alive Memory. A portion of the memory within the PCM that must have power even when the vehicle is not operating. KAPWR: Keep Alive Power. Dedicated, unswitched power circuit that maintains KAM. Key On Engine Off Self- Test: A test of the EEC system conducted by the PCM with power applied and the engine at rest. Key On Engine Running Self- Test: A test of the EEC system conducted by the PCM with the engine running and the vehicle at rest. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4551 KEYPWR: Key Power. Battery voltage supplied when the ignition key is in the ON position. Knock: The sharp metallic sound produced when two combustion pressure fronts collide in the combustion chamber of an engine. KOEC: Key On Engine Continuous. KOEO: Key On Engine off. KOER: Key On Engine Running. KPA: Kilopascal. Unit of pressure. 3.386 kPa = 1 inch of mercury (Hg.). KPH: Kilometers Per Hour. KS: Knock Sensor. Detects engine knock. L: Liters. The unit of volume in the metric measuring system. One liter equals 1.06 quarts. LEV: Low Emissions Vehicle. LFC: Low Fan Control. LFP: Low Fuel Pump. Reduced operating speed for multi-speed fuel pumps. LIFO: Last In First Out. LILO: Last In Last Out. LONGFT1, LONGFT2: Long-Term Fuel Trim. Fuel flow adjustment determined by the PCM. LOOP: indicates OPEN or CLOSED loop status. LPG: Liquefied Petroleum Gas. LPLR: Low Pressure Low Resistance fuel injector. M-V ACRONYMS AND DEFINITIONS NOTE: This Acronyms and Definitions listing contains technical terms applicable to Ford Motor Company products. It is not intended to be an all-inclusive dictionary of components and their functions. If a detailed description of a particular system or component is desired, refer to the applicable Vehicle System for the specific vehicle being serviced. M-85: Fuel containing 85% methanol alcohol. MAF: Mass Air Flow. Used to measure the mass (weight) of the air entering the engine. MAF RTN: Mass Air Flow Return. A return circuit for the MAF sensor. MAP: Manifold Absolute Pressure. The internal pressure of the intake manifold. MFC: Medium Fan Control. MFI: Multiport Fuel Injection. A fuel-delivery system in which each cylinder is individually fueled. MFP: Modulated Fuel Pump. Microprocessor: A digital processor on a chip which perform arithmetic and control logic. MIL: Malfunction Indicator Lamp. An indicator lamp alerting the driver of an emission related malfunction. May also read "CHECK ENGINE" or "SERVICE ENGINE SOON." MISF: Misfire. Any event in the cylinder that causes a sudden change in acceleration of the crankshaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4552 MON: Motor Octane Number. Monolithic Substrate: The ceramic honeycomb structure used in the catalytic converter. MSOF: Manual Shift-on-the-Fly. MY: Model Year. NA: Naturally Aspirated. Engine that is not supercharged or turbocharged. NAAO: North American Automotive Operations. NC: Normally Closed. NG: Natural Gas. A system capable of using natural gas for vehicle operation. NGS: New Generation STAR (Self-Test Automatic Readout) tester. NGVM: Natural Gas Vehicle Module. NO: Norm ally Open. NO(x): Oxides of Nitrogen. Formed at high combustion temperatures. NVH: Noise, Vibration, Harshness. A classification of vehicle concerns. OASIS: On-Line Automotive Service Information System. OBD, OBD-II: On-Board Diagnostics, On-Board Diagnostics Second Generation. A system that monitors PCM input and output control signals. On Demand Test: Technician initiated "KOEO" and "KOER" tests performed by the PCM. OC: Oxidation Catalytic converter. A catalytic converter system that reduces levels of HC and CO. OCT ADJ: Octane Adjust. Compensating strategy that adjusts for changes in fuel octane. OEM: Original Equipment Manufacturer. OHC: OverHead Cam. An engine configuration that uses a single camshaft positioned above the valves. OWL: Overheat Warning Lamp or its signal output from the PCM. Turns the TEMP warning lamp ON when engine oil temperature exceeds safe limits. Open Circuit: A circuit which does not provide a complete path for flow of current. OL: Open Loop. An operating condition based on instructions not modified by PCM feedback. O(2)S 11/12/21/22: Oxygen Sensor and its relative position in the exhaust system. Detects oxygen content in exhaust gasses. OSC: Output State Control. OSS: Output Shaft Speed. Ozone: A blue gaseous form of oxygen (O(3)) formed naturally by electric discharge or exposure to ultraviolet radiation. Particulate: Small solid matter found in exhaust gases, especially prevalent in diesel engines. PATS: Passive Anti-Theft System. PATSIL: Passive Anti-Theft System Indicator Light. PATSIN: Passive Anti-Theft System Receive Signal. PATSOUT: Passive Anti-Theft System Transmit Signal. PATSTRT: Passive Anti-Theft System Starter Relay Control Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4553 PCM: Powertrain Control Module. Formerly known as the EEC (Electronic Engine Control) Processor. PCV: Positive Crankcase Ventilation. A system which allows the controlled flow of crankcase vapors into the combustion chamber. PF: Purge Flow. Amount of fuel vapor burned in the engine. Photochemical: Term describing the action of light on air pollutants which results in creating smog. PID: Parameter Identifier. Identifies an address in PCM memory which contains operating information. Powertrain: Engine and transmission/transaxle components. Pressure - Absolute: A pressure referenced to a perfect vacuum. Pressure - Atmospheric: The pressure of the surrounding air at any given temperature and altitude. Sometimes called Barometric Pressure. Pressure - Barometric: Pertaining to atmospheric pressure or the results obtained by a barometer. Pressure - Differential: The pressure difference between two regions, such as between the intake manifold and atmospheric pressure. Pressure - Gage: The amount by which absolute pressure exceeds the ambient atmospheric pressure. PIP: Profile Ignition Pickup. Provides crankshaft position information for ignition synchronization. Potentiometer: An adjustable resistance component commonly used as a sensor (Example: TP Sensor). PPM: Parts Per Million. A measure used in emission analysis. PROM: Programmable Read-Only Memory. Similar to ROM except without program instructions. Protocol: A set of rules for the exchange of information on a network. PSOM: Programmable Speedometer/Odometer Module. A module that processes vehicle speed information. PSP: Power Steering Pressure. Indicates the pressure in the power steering system. PSP V: Power Steering Pressure Input Voltage. PTEC: Powertrain Electronic Controller. PTO: Power Take-Off. PW: Pulse Width. The length of time an actuator, such as a fuel injector, remains energized. PWM: Pulse Width Modulation. Controls the intensity of an output by varying the signal duty cycle. PWR GND: Power Ground. The main ground circuit in the EEC system. Quick Test: A series of diagnostic tests of the EEC system consisting of KOEO, KOER and Continuous Memory Self-Tests. Results are displayed as a series of DTCs. RABS: Rear Antilock Brake System. RAM: Random Access Memory. Memory into which information can be written as well as read. REDOX: Reduction Oxidation Catalytic converter. A catalytic converter system designed to operate at high temperatures. Regulator: Controls the alternator/generator field current to maintain proper battery charge. Contained within the PCM in smart charging applications. Relay: An electromechanical device in which connections in one circuit are opened or closed by changes in another circuit. REM: Rear Electronic Module. Repetitive Spark: Multiple firings of individual spark plugs at engine speeds below 1000 RPM to improve idle quality and improve emissions. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4554 RF: Radio Frequency. RFI: Radio Frequency Interference. RFS: Returnless Fuel System. RM: Relay Module. A module containing two or more relays. ROM: Read-Only Memory. Computer memory that can be accessed and utilized, but not altered. RON: Research Octane Number. Routine: A group of related tasks, such as a series of diagnostic tests. RPM: Revolutions Per Minute. RS: Reverse Switch. RTN: Return. A dedicated sensor ground circuit. RWD: Rear Wheel Drive. SAE: Society of Automotive Engineers. SBS: Supercharger Bypass Solenoid or its signal output from the PCM. SC: Supercharged or Supercharger. SCB: Supercharger Bypass Control. A system that allows manifold vacuum to be bled away from the supercharger wastegate actuator to allow for maximum boost. SCBF: Supercharger Bypass Control Fault. Identifies whether a fault exists in the Supercharger Bypass circuit. SCICP: Supercharger Intercooler Pump Control. SCICPF: Supercharger Intercooler Pump Control Fault. SCIPC: The PID to monitor the operation of the Supercharger and Charge Air Cooler pump. SCP: Standard Corporate Protocol. Self- Test: See Quick Test. Sensor: A device that detects the value or change in a physical quantity, such as temperature, pressure or flow rate, and converts the data into an electrical signal. SFI: Sequential Multi port Fuel Injection. A multiport fuel delivery system where each injector is individually energized and timed relative to its cylinder intake event. Shield: A conducting sleeve that surrounds wires to be electronically isolated from Electromagnetic Interference (EMI). Short Circuit: An undesirable condition in a circuit where it is terminated at a point other than that intended. SHRT FT: Short-Term Fuel Trim. Fuel flow adjustment in response to the HO2S sensor(s) input during closed-loop operation. SIG RTN: Signal Return. A dedicated sensor ground circuit that is common to two or more sensors. SIL: Shift Indicator Lamp. Smart Driver: A PCM or ECU output driver that can detect faults (open or shorts) on its output circuit. SME: Society of Manufacturing Engineers. SOF: Shift-On-the-Fly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4555 SOHC: Single Overhead Cam. Solenoid: A device consisting of an electrical coil which produces a magnetic field in a plunger and pulled to a central position. ST: Scan Tool. A device that interfaces with and communicates information on a data link. Stoichiometry: An air/fuel mixture that is neither too rich nor too lean. Stoichiometric ratio is 14.7 parts of air for every 1 part of fuel. Switch: A device for making, breaking, or changing the connections in an electrical circuit. TA: Traction Assist. TACH: Tachometer. TB: Throttle Body. A device that controls airflow through the engine via a butterfly valve, and has an air bypass channel around the throttle plate. TC: 1. Traction Control. Combines anti-lock braking and axle torque reduction to control wheel slippage. 2. Turbocharger. TDC: Top Dead Center. Tear Tag: The two-piece adhesive label attached to the PCM to identify its calibration. Thermistor: A temperature dependent resistor, like that used in CHT and ECT sensors. Timing: Relationship between spark plug firing and piston position expressed in crankshaft degrees before (BTDC) or after (ATDC) top dead center of the compression stroke. TMAP: Thermal Manifold Absolute Pressure Sensor. A MAP Sensor that includes a thermistor to measure intake air temperature. TP: Throttle Position (sensor). A three-wire potentiometer that provides throttle angle and rate information for the PCM. TP V: Throttle Position Sensor Voltage. Transducer: A device that receives energy from one medium and transfers it to another. For example, thermal energy is converted to an electrical signal through a temperature probe. Transmissions/Transaxles: NOTE: All related items are grouped under the general heading "TRANSMISSIONS" located at the end. TSB: Technical Service Bulletin. Notifies service personnel of any known vehicle concerns, procedures, or general service information. Underspeed Mode: A control mode that prevents the engine from stalling in the event it stumbles while running. Also used during engine crank. Vacuum: Manifold pressure that is reduced below the ambient atmospheric pressure. Variable Reluctance: A process of passing a varying magnetic field through wire windings and inducing a voltage. VCT: Variable Camshaft Timing. VECI: Vehicle Emission Control Information label. VIN: Vehicle Identification Number. A unique identification number given to every vehicle produced. Includes information about the year, model, engine, and plant origin of the vehicle. VMV: Vapor Management Valve. Controls the flow of fuel vapors out of the carbon canister. VOM: Volt-Ohm Meter. Readings are indicated by sweep hand on a printed scale rather than a digital (DVOM) display. VPWR: Vehicle Power. A switched circuit that provides power to the EEC system. Compare "Battery Voltage VREF: Reference Voltage. A dedicated circuit that provides approximately a 5.0 volt signal used as a reference by certain sensors. WAC: Wide Open Throttle A/C Cut-off. Turns A/C system off during wide open throttle or certain other operating conditions. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4556 Wastegate Control: A device that opens the wastegate in case of overboost from a turbocharger. WOT: Wide Open Throttle. A condition of maximum airflow through the throttle body. Zip Tube: Another name for "fresh air duct" or "air inlet duct". TRANSMISSIONS: NOTE: The transmission naming convention is as follows: ^ The first character, a number, is the number of forward gears. ^ The second character, either the letter "F" or "R," represents front (transaxle) or rear (transmission) wheel drive. ^ The next set of characters, a grouping of numbers, represents the design torque capacity of the transmission/transaxle (for example, "27" represents 270ft./lbs. in the 4F27E transaxle). ^ The last character, if used, is one of the following: ^ "E" for electronic shift ^ "N" for non-synchronous shift ^ "S" for synchronous shift ^ "W" for wide ratio ^ 4F27E: Also known as the FN Focus automatic transmission. ^ 4F44E: Formerly known as the CD4E. ^ 4F46S: Formerly known as the Ax45 and regular-duty AXOD-E. ^ 4F50N: Formerly known as the Ax4N and heavy-duty AXOD-E. ^ 4R44E: Formerly known as A4LD for 3.0L applications. ^ 4R55E: Formerly known as A4LD for 4.0L applications. ^ 4R70W: Formerly known as AOD-E. ^ 4R100: Formerly known as E4OD. ^ 5R44E: Formerly known as A5LD for 3.0L applications. ^ 5R55E: Formerly known as A5LD for 4.0L applications. ^ 5R55N: Lincoln LS automatic transmission. ^ 5R55W: Wide-ratio truck transmission. ^ 4x4L: 4x4 Low. ^ A/T: Automatic Transmission. ^ CCS: Coast Clutch Solenoid. ^ CCSF: Coast Clutch Solenoid Fault. Displays a YES if fault exists. ^ EPC: Electronic Pressure Control. ^ EPCV: Electronic Pressure Control Volts. ^ ESS: Electronic Shift Scheduling. ^ HCDSS: High Clutch Drum Speed Sensor. PCM input from the 4R44E and 4R55E. ^ M5OD: Manual 5-Speed transmission with overdrive (RWD). ^ M/T: Manual Transmission/Transaxle. ^ NPS: Neutral Pressure Switch or its signal input to the PCM. ^ OCS: Overdrive Cancel Switch. ^ OSS: Output Shaft Speed. Indicates rotational speed of the transmission output shaft. ^ PNP: Park/Neutral Position switch. Also known as Neutral Drive Switch (NDS), Neutral Gear Switch (NGS), and Transmission Switch Neutral (TSN). ^ REVERSE or REV: Transmission Reverse Switch Input. ^ SIL: Shift Indicator Lamp. A lamp that indicates the preferred shift points on select manual transmission/transaxle vehicles. ^ S91/SS2/SS3: Shift solenoids. Devices that control the shifting in an automatic transmission. ^ TCC: Torque Converter Clutch. When energized, causes a mechanical engagement and disengagement of the Torque Converter Clutch. ^ TCIL: Transmission Control Indicator Lamp. Indicates that the Transmission Control Switch (TCS) has been activated. ^ TCS: Transmission Control Switch. Modifies the operation of electronically controlled transmissions. ^ Torque converter: A device which by its design multiplies the torque in a fluid coupling between an engine and transmission/transaxle. ^ TFT: Transmission Fluid Temperature. Indicates temperature of transmission fluid. ^ Transaxle: A device consisting of a transmission and axle drive gears assembled in the same case. Front-wheel drive applications. ^ Transmission: A device which selectively increases or decreases the ratio of relative rotation between its input and output shafts. Rear-wheel drive applications. ^ TR: Transmission Range. The range in which the transmission is operating. ^ TR Sensor: Formerly known as Manual Lever Position Sensor (MLPS). Provides information to the PCM on the transmission range selector position. ^ TR V: Transmission Range Voltage. ^ TSS: Turbine Shaft Speed. Indicates rotational speed of the transmission turbine shaft. ^ VSS: Vehicle Speed Sensor. A magnetic pickup device that generates an AC signal that is proportional to vehicle speed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4557 Catalytic Converter: Description and Operation Catalyst Efficiency Monitor - Federal Test Procedure Catalyst Efficiency Monitor - Federal Test Procedure The Catalyst Efficiency Monitor uses an oxygen sensor before and after the catalyst to infer the hydrocarbon efficiency based on oxygen storage capacity of the catalyst. Under normal, close-loop fuel conditions, high efficiency catalysts have significant oxygen storage. This makes the switching frequency of the rear Heated Oxygen Sensor (HO2S) very slow and reduces the amplitude of those switches as compared to the switching frequency and amplitude of the front HO2S. As the catalyst efficiency deteriorates, its ability to store oxygen declines. The post-catalyst or downstream HO2S signal begins to switch more rapidly with increasing amplitude, approaching the switching frequency and amplitude of the pre-catalyst or upstream HO2S. All applications utilize an FTP-based (Federal Test Procedure) catalyst monitor. This simply means that the catalyst monitor must run during a standard FTP emission test as opposed to the 20-second steady state catalyst monitor used in 1994 through some 1996 vehicles. Two slightly different versions of the catalyst monitor are used in the 2001 model year. Switch Ratio Method (1996 - 2001) 1. In order to assess catalyst oxygen storage, the monitor counts front and rear HO2S switches during part-throttle, close-loop fuel condition after the engine is warmed-up and inferred catalyst temperature is within limits. Front switches are accumulated in up to nine different air mass regions or cells although three air mass regions is typical. Rear switches are counted in a single cell for all air mass regions. When the required number of front switches has accumulated in each cell, the total number of rear switches is divided by the total number of front switches to compute a switch ratio. A switch ratio near 0.0 indicates high oxygen storage capacity, hence high HC efficiency. A switch ratio near 1.0 indicates low oxygen storage capacity, hence low HC efficiency. If the actual switch ratio exceeds a calibrated threshold switch ratio, the catalyst is considered failed. Inputs from Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CHT) (warm engine), IAT (not extreme ambient temperatures), Mass Air Flow (MAF) (greater than minimum engine load), Vehicle Speed Sensor (VSS) (within vehicle speed widow) and Throttle Position (TP) (at part-throttle) are required to enable the Catalyst Efficiency Monitor. 2. The DTCs associated with this test are Diagnostic Trouble Code (DTC) P0420 (Bank 1) and P0430 (Bank 2). Because an Exponentially Weight Moving Average algorithm is use for malfunction determination, up to six driving cycles may be required to illuminate the Malfunction Indicator Lamp (MIL) during normal customer driving. If Keep Alive Memory (KAM) is reset, a malfunction will illuminate the MIL in 2 drive cycles. Index Ratio Method (some 2001 and beyond) 1. In order to assess catalyst oxygen storage, the catalyst monitor counts front HO2S switches during part-throttle, closed-loop fuel conditions after the engine is warmed-up and inferred catalyst temperature is within limits. Front switches are accumulated in up to three different air mass regions or cells. While catalyst monitoring entry conditions are being met, the front and rear HO2S signal lengths are continually being calculated. When the required number of front switches has accumulated in each cell, the total signal length of the rear HO2S is divided by the total signal length of the front HO2S to compute a catalyst index ratio. An index ratio near 0.0 indicates high oxygen storage capacity, hence high efficiency. A switch ratio near 1.0 indicates low oxygen storage capacity, hence low HC efficiency. If the actual index ratio exceeds the threshold index ratio, the catalyst is considered failed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4558 Inputs from ECT or CHT (warm engine), IAT (not extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed widow) and TP (at part-throttle) are required to enable the Catalyst Efficiency Monitor. 2. The DTCs associated with this test are DTC P0420 (Bank 1) and P0430 (Bank 2). Because an Exponentially Weighted Moving Average algorithm is use for malfunction determination, up to six driving cycles may be required to illuminate the MIL during normal customer driving. If KAM is reset, a malfunction will illuminate the MIL in 2 drive cycles. If the catalyst monitor does not complete during a particular driving cycle, the already accumulated switch/signal data is retained in Keep Alive Memory and is used during the next driving cycle to allow the catalyst monitor a better opportunity to complete. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4559 Catalytic Converter: Description and Operation Catalyst and Exhaust Systems Catalyst and Exhaust System Overview The Catalytic Converter and Exhaust Systems (Figure 135) work together to control the release of harmful engine exhaust emissions into the atmosphere. The engine exhaust gas consists mainly of Nitrogen (N), Carbon Dioxide (CO2) and Water Vapor (H2O). However, it also contains Carbon Monoxide (CO), Oxides Of Nitrogen (NOx), Hydrogen (H), and various unburned Hydrocarbons (HCs). CO, NO(x), and HCs are major air pollutants, and their emission into the atmosphere must be controlled. The exhaust system generally consists of an exhaust manifold, front exhaust pipe, upstream Heated Oxygen Sensor (HO2S), rear exhaust pipe, downstream HO2S, a muffler and an exhaust tailpipe. The catalytic converter is installed between the front and rear exhaust pipes. Catalytic converter efficiency is monitored by the On Board Diagnostic (OBD II) system. Generic Catalyst and Exhaust System Catalytic Converter A catalyst is a material that remains unchanged when it initiates and increases the speed of a chemical reaction. A catalyst will also enable a chemical reaction to occur at a lower temperature. The concentration of exhaust gas products released to the atmosphere must be controlled. The catalytic converter assists in this task. It contains a catalyst in the form of a specially treated honeycomb structure saturated with catalytically active precious metals. As the exhaust gases come in contact with the catalyst, they are changed into mostly harmless products. The catalyst initiates and speeds up heat producing chemical reactions of the exhaust gas components so they are used up as much as possible. Exhaust System The purpose of the exhaust system is to convey engine emissions from the exhaust manifold to the atmosphere. Engine exhaust emissions are directed from the engine exhaust manifold to the catalytic converter through the front exhaust pipe. An HO2S is mounted on the front exhaust pipe before the catalyst. The catalytic converter reduces the concentration of Carbon Monoxide (CO), unburned Hydrocarbons (HCs) and Oxides of Nitrogen (NO) in the exhaust emissions to an acceptable level. The reduced exhaust emissions are directed from the catalytic converter to a muffler through the rear exhaust pipe. Another HO2S is mounted on the rear exhaust pipe. Lastly, the exhaust emissions are directed to the atmosphere through an exhaust tailpipe. HARDWARE The downstream HO2S may be located after the light off catalyst or underbody catalyst. The underbody catalyst may be in-line with the light off catalyst, or the underbody catalyst may be common to two light off catalysts, forming a "Y" pipe configuration. For an exact configuration of the catalyst and exhaust system, refer to Exhaust System. Three Way Catalytic Converter The Three Way Catalytic (TWC) converter contains either platinum (Pt) and Rhodium (Rh) or Palladium (Pd) and Rhodium (Rh). The TWC converter catalyzes the oxidation reactions of unburned HCs and CO and the reduction reaction of NO. The three-way conversion can be best accomplished by always operating the engine air fuel/ratio at or close to stoichiometry. Exhaust Manifold/Runners The exhaust manifold runners collect exhaust gases from engine cylinders. The number of exhaust manifolds and exhaust manifold runners depends on the engine configuration and number of cylinders. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Acronyms and Definitions > Page 4560 Exhaust Pipes Exhaust pipes are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The pipes serve as guides for the flow of exhaust gases from the engine exhaust manifold through the catalytic converter and the muffler. Upstream Heated and Downstream Heated Oxygen Sensors The HO2S provide the Powertrain Control Module (PCM) with voltage and frequency information related to the oxygen content of the exhaust gas. In addition to providing the PCM with indications of how rich/lean the engine is operating, the upstream HO2S signal serves as an input to the HO2S monitor. The downstream HO2S signal is an input to the Catalyst Efficiency monitor. Muffler Mufflers are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The muffler reduces the level of noise produced by the engine, and it also reduces the noise produced by exhaust gases as they travel from the catalytic converter to the atmosphere. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 4561 Catalytic Converter: Testing and Inspection For information regarding diagnosis of this system refer to Computers and Control Systems Diagnosis. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 4562 Catalytic Converter: Service and Repair Removal 1. Remove the muffler assembly. 2. Disconnect the heated oxygen sensor (HO2S) connectors. 3. Remove the bolts. 4. Remove the bolts and nuts. 5. Remove the LH three way catalytic converter (TWC). 6. Remove the bolts. 7. Twist and remove the RH TWC. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 4563 Installation 1. Note: Before installing the TWCs, install new gaskets. Follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications Canister Purge Control Valve: Specifications Canister Purge Valve Bracket Retaining Bolt 25 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications > Page 4568 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications > Page 4569 Canister Purge Control Valve: Service Precautions WARNING: ^ THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications > Page 4570 Canister Purge Control Valve: Description and Operation EVAP Canister Purge Valve EVAP Canister Purge Valve EVAP Canister Purge Valve The EVAP canister purge valve (Figure 95) and (Figure 96) is the part of the Enhanced EVAP system that is controlled by the PCM. This valve controls the flow of vapors (purging) from the EVAP canister to the intake manifold during various engine operating modes. The EVAP canister purge valve is normally closed valve. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications > Page 4571 Canister Purge Control Valve: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 2. Remove the battery tray. For additional information, refer to Battery. 3. Disconnect the tubes. 1 Disconnect the electrical connector. 2 Disconnect the tubes from the evaporative emission canister purge valve (EVAP canister purge valve). WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 4. Disconnect the evaporative emission canister purge valve and bracket. ^ Remove the bolt. 5. Remove the evaporative emission canister purge valve. 1 Disconnect the vacuum line from the evaporative emission canister purge valve. 2 Remove the evaporative emission canister purge valve. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications > Page 4572 1. To install, reverse the removal procedure. ^ Leak test the evaporative emissions system. For additional information, refer to Evaporative Emission System Leak Test. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. For additional information, refer to Evaporative Emission Repair Verification Drive Cycle. See: Service and Repair Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Service and Repair Evaporative Canister Filter: Service and Repair REMOVAL 1. Open the liftgate, lower and remove the spare tire. 2. Disconnect the battery ground cable. For additional information refer to Battery. WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 3. Disconnect the two chassis emissions lines from the evaporative emission tube. WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 4. Remove the evaporative emissions canister bolts. 5. Remove the evaporative emission canister with bracket assembly. 1 Disconnect the canister vent solenoid electrical connector. 2 Remove the EVAP canister with bracket assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Canister Filter > Component Information > Service and Repair > Page 4576 6. Disconnect the canister vent hose. 7. Remove the evaporative emission dust separator. INSTALLATION 1. To install, reverse the removal procedure. ^ Leak test the evaporative emission system. For additional information, refer to Evaporative Emission System Leak Test. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. For additional information, refer to Evaporative Emission Repair Verification Drive Cycle. See: Service and Repair Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications Evaporative Emission Control Canister: Specifications Evaporative Emissions Canister Bolts 25 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 4580 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 4581 Evaporative Emission Control Canister: Service Precautions WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Description and Operation > Description and Operation Evaporative Emission Control Canister: Description and Operation The Evaporative Emissions (EVAP) canister: ^ is located under the rear of the vehicle. ^ contains activated carbon. ^ stores fuel vapors. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Description and Operation > Description and Operation > Page 4584 Evaporative Emission Control Canister: Description and Operation Principles of Operation (How Does It Work ?) Fuel vapors from the fuel tank are stored in the EVAP canister. When the engine is running, the vapors are purged from the EVAP canister for combustion. OBD II vehicles sometimes use multiple canisters, which is dependent upon the size and number of the fuel tanks used on a specific vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Description and Operation > Page 4585 Evaporative Emission Control Canister: Service and Repair REMOVAL 1. Open the liftgate, lower and remove the spare tire. 2. Disconnect the battery ground cable. For additional information refer to Battery. WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 3. Disconnect the two chassis emissions lines from the evaporative emission tube. WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 4. Remove the evaporative emissions canister bolts. 5. Remove the evaporative emission canister with bracket assembly. 1 Disconnect the canister vent solenoid electrical connector. 2 Remove the EVAP canister with bracket assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Description and Operation > Page 4586 6. Remove the canister vent solenoid and the evaporative emission tube. 1 Disconnect the canister vent solenoid hose from the canister vent solenoid. 2 Remove the canister vent solenoid. 3 Remove the evaporative emission canister purge sleeve. 4 Remove the evaporative emission tube. 7. Remove the evaporative emission canister from the evaporative emission canister bracket. INSTALLATION 1. To install, reverse removal procedure. ^ Leak test the evaporative emissions system. For additional information, refer to Evaporative Emission System Leak Test. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. For additional information, refer to Evaporative Emission Repair Verification Drive Cycle. See: Service and Repair NOTE: Lubricate all O-ring seals with MERPOL(R) O-ring Seal Lubricant or equivalent meeting Ford specification ESE-M99B144-B. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative System Service Port > Component Information > Description and Operation Evaporative System Service Port: Description and Operation The Evaporative Emission (EVAP) system test port: ^ is located on the EVAP canister purge outlet tube near the EVAP canister purge valve. ^ is used to connect the Evaporative Emissions System Leak Tester to the EVAP system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative System Service Port > Component Information > Description and Operation > Page 4590 Evaporative System Service Port: Service and Repair REMOVAL 1. Remove the clip. 2. Disconnect the hoses. 3. Remove the test port assembly. ^ Disconnect the fitting. ^ Remove the test port assembly. INSTALLATION 1. To install, reverse the removal procedure. ^ Leak test the evaporative emissions system. For additional information, refer to Evaporative Emission System Leak Test. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. For additional information, refer to Evaporative Emission Repair Verification Drive Cycle. See: Service and Repair Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Solenoid, Evaporative System > Component Information > Description and Operation Leak Detection Solenoid: Description and Operation Canister Vent Solenoid Typical Canister Vent (CV) Solenoid During the Enhanced EVAP System test monitor, the Canister Vent (CV) solenoid (Figure 99) seals the EVAP canister from atmospheric pressure. This allows the EVAP canister purge valve to obtain the target vacuum in the fuel tank during the monitor run. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Service Precautions > Technician Safety Information Leak Detection Valve: Technician Safety Information WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Service Precautions > Technician Safety Information > Page 4599 Leak Detection Valve: Vehicle Damage Warnings CAUTION: ^ The canister vent solenoid must not be energized for more than nine minutes at one time. Once the canister vent solenoid is energized and de-energized, adequate time must be allowed for the component to cool adequately. Failure to allow the component to cool may create a false failure in the diagnostics, causing unnecessary repairs. ^ The evaporative emission system must not be pressurized to more than 3.48 kPa (14 inches/H2O) or damage to the evaporative emission system may occur. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Description and Operation > Description and Operation Leak Detection Valve: Description and Operation The canister vent solenoid: ^ is normally open. ^ seals the evaporative emissions system for the Inspection And Maintenance (I/M 240) test and OBD II leak and pressure tests. ^ is mounted to the evaporative emissions canister bracket. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Description and Operation > Description and Operation > Page 4602 Leak Detection Valve: Description and Operation Principles of Operation (How Does It Work ?) During the Evaporative Emission Running Loss System Monitor Test, Evaporative Emissions Repair Verification Drive Cycle, and the Evaporative Emission System leak Test, the canister vent solenoid is closed to allow either a vacuum to be drawn on the fuel tank or to hold a specified pressure in the system. The canister vent solenoid is normally open. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Service and Repair > Canister Vent Solenoid Leak Detection Valve: Service and Repair Canister Vent Solenoid REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 2. Remove the Evaporative Emissions (EVAP) canister. For additional information, refer to Evaporative Emission Control Canister. 3. Remove the canister vent solenoid. INSTALLATION 1. To install, reverse the removal procedure. ^ Leak test the evaporative emission canister and bracket assembly. For additional information, refer to Evaporative Emission System Leak Test. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. For additional information, refer to Evaporative Emission Repair Verification Drive Cycle. See: Service and Repair Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Service and Repair > Canister Vent Solenoid > Page 4605 Leak Detection Valve: Service and Repair Canister Vent Solenoid Closing Procedure Worldwide Diagnostic System (WDS) SPECIAL SERVICE TOOL(S) CAUTION: The canister vent solenoid must not be energized for more than nine minutes at one time. Once the canister vent solenoid is energized and de-energized, adequate time must be allowed for the component to cool adequately. Failure to allow the component to cool may create a false failure in the diagnostics, causing unnecessary repairs. 1. Connect the scan tool and select the output test mode. 2. Select the Fuel Tank Pressure (FTP) and the volts (V) Parameter Identification (PID) for monitoring. 3. Select the ALL OFF mode. 4. Close the canister vent solenoid by pushing the START button on the scan tool. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid Vapor Separator, Evaporative System > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid Vapor Separator, Evaporative System > Component Information > Locations > Page 4609 Liquid Vapor Separator: Service Precautions WARNING: ^ THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR 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. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid Vapor Separator, Evaporative System > Component Information > Locations > Page 4610 Liquid Vapor Separator: Description and Operation The Fuel Vapor Vent Valve (FVV) assembly is mounted on the top of the fuel tank. It is used to control the flow of fuel vapors entering the EVAP system. The head portion of the assembly prevents the fuel tank from overfilling during refueling. The assembly also has a spring float, which prevents liquid fuel from entering the vapor delivery system under severe handling or vehicle rollover conditions. In the upright position, the open bottom of the float will lift and shut off the orifice. Under severe handling conditions, the spring will push the float closed when angles allow liquid fuel to reach the orifice. In a rollover condition, the weight of the open bottom float and spring pressure will close the orifice. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid Vapor Separator, Evaporative System > Component Information > Locations > Page 4611 Liquid Vapor Separator: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 2. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR 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. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 3. Drain the fuel tank. For additional information, refer to Fuel Delivery and Air Induction. 4. Lower the fuel tank. For additional information, refer to Fuel Delivery and Air Induction. 5. Remove the EVAP canister tube from the fuel vapor vent valve. 6. Remove the fuel vapor vent valve. ^ Press down and rotate the fuel vapor vent valve counterclockwise and remove it from the fuel tank. INSTALLATION 1. To install, reverse the removal procedure. ^ Leak test the evaporative emissions system. For additional information, refer to Evaporative Emission System Leak Test. See: Testing and Inspection/Component Tests and General Diagnostics/Component Tests/Evaporative Emission System Leak Test ^ Carry out the evaporative emission repair verification drive cycle. For additional information, refer to Evaporative Emission Repair Verification Drive Cycle. See: Service and Repair Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Specifications EGR Electronic Vacuum Regulator Solenoid: Specifications EGR Vacuum Regulator Solenoid Nuts 8 - 12 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Specifications > Page 4616 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Specifications > Page 4617 EGR Electronic Vacuum Regulator Solenoid: Description and Operation EGR VACUUM REGULATOR SOLENOID EGR Vacuum Regulator Solenoid Test Graph EGR Vacuum Regulator Solenoid Data Chart The EGR vacuum regulator solenoid (Figure 88) is an electromagnetic device which is used to regulate the vacuum supply to the EGR valve. The solenoid contains a coil which magnetically controls the position of a disc to regulate the vacuum. As the duty cycle to the coil increases, the vacuum signal passed through the solenoid to the EGR valve also increases. Vacuum not directed to the EGR valve is vented through the solenoid vent to atmosphere. Note that at 0% duty cycle (no electrical signal applied), the EGR vacuum regulator solenoid allows some vacuum to pass, but not enough to open the EGR valve. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Specifications > Page 4618 EGR Electronic Vacuum Regulator Solenoid: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the (A) electrical connector and the (B) vacuum hoses from the Exhaust Gas Recirculation (EGR) vacuum regulator solenoid. 3. Remove the nuts and the EGR vacuum regulator solenoid. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications EGR Tube: Specifications EGR Tube Bracket (Upper) Bolt 7.6 - 10.4 Nm EGR Tube Fittings (Lower) 34 - 46 Nm EGR Tube Fittings (Upper) 34 - 46 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications > Page 4622 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications > Page 4623 EGR Tube: Description and Operation ORIFICE TUBE ASSEMBLY Orifice Tube Assembly The orifice tube assembly (Figure 90) is a section of tubing connecting the exhaust system to the intake manifold. The assembly provides the flow path for the EGR to the intake manifold and also contains the metering orifice and two pressure pick-up tubes. The internal metering orifice creates a measurable pressure drop across it as the EGR valve opens and closes. This pressure differential across the orifice is picked up by the differential pressure feedback EGR sensor which provides feedback to the PCM. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Lower EGR Tube: Service and Repair Lower REMOVAL 1. Disconnect the EGR pressure transducer hoses. 2. Disconnect the lower EGR tube fittings. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Lower > Page 4626 EGR Tube: Service and Repair Upper REMOVAL 1. Remove the EGR valve. 2. Remove the air cleaner outlet tube. For additional information, refer to Fuel Delivery and Air Induction. 3. Release the tension on the accessory drive belt and position the belt aside. 4. Remove the bolt. 5. Remove the bolts and position the engine accessory bracket forward. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Lower > Page 4627 6. Remove the bolt. 7. Remove the upper EGR tube. 1 Inspect the O-ring seal and install a new O-ring seal if necessary. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications EGR Valve: Specifications EGR Valve Bolts 20 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 4631 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Differential Pressure Feedback EGR EGR Valve: Description and Operation Differential Pressure Feedback EGR EXHAUST GAS RECIRCULATION VALVE EGR Valve Test Graph The EGR valve (Figure 89) in the Differential Pressure Feedback EGR system is a conventional, vacuum-actuated EGR valve. The valve increases or decreases the flow of exhaust gas recirculation. As vacuum applied to the EGR valve diaphragm overcomes the spring force, the valve begins to open. As the vacuum signal weakens, at 5.4 kPa (1.6 in-Hg) or less, the spring force closes the valve. The EGR valve is fully open at about 15 kPa (4.5 in-Hg). Since EGR flow requirement varies greatly, providing service specifications on flow rate is impractical. The on-board diagnostic system monitors the EGR valve function and triggers a Diagnostic Trouble Code if the test criteria is not met. The EGR valve flow rate is not measured directly as part of the field diagnostic procedures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Differential Pressure Feedback EGR > Page 4634 EGR Valve: Description and Operation Electric Motor EGR System (EEGR) ELECTRIC EGR VALVE Electric EGR Motor/Valve Assembly Electric EGR The electric EGR valve (Figure 92) and (Figure 93) is a water cooled motor/valve assembly. The motor is commanded to move in 52 discrete steps as it acts directly on the the EGR valve. The position of the valve determines the rate of EGR. The built in spring works to close the valve (against the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Differential Pressure Feedback EGR > Page 4635 motor opening force). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Page 4636 EGR Valve: Service and Repair REMOVAL 1. Disconnect the EGR valve vacuum connection. 2. Disconnect the EGR tube upper fitting. 3. Remove the EGR valve bolts and the EGR valve. INSTALLATION 1. To install, reverse the removal procedure. ^ Carefully clean all sealing surfaces and install a new EGR valve gasket. NOTE: The EGR valve sealing surfaces are soft metals. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of 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). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4645 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4646 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4647 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4648 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4649 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of 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). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4655 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4656 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4657 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4658 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4659 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4664 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4665 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4666 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4672 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4673 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4674 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4675 Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR Bolts 8 - 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4676 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4677 Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4678 Tube Mounted Differential Pressure Feedback EGR Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4679 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the differential pressure feedback EGR electrical connector. 3. Disconnect the differential pressure feedback EGR hoses. 4. Remove the bolts and the differential pressure feedback EGR. INSTALLATION 1. Fit the differential pressure feedback EGR and loosely install the bolts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4680 2. Tighten the bolts. 3. Connect the differential pressure feedback EGR hoses. 4. Connect the differential pressure feedback EGR electrical connector. 5. Connect the battery ground cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Service Precautions Positive Crankcase Ventilation: Service Precautions CAUTION: Do not remove the PCV system from the engine. Removal of the PCV system will adversely affect the fuel economy and engine ventilation and result in shorter engine life. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Acronyms and Definitions Positive Crankcase Ventilation: Description and Operation Acronyms and Definitions 2V - L ACRONYMS AND DEFINITIONS NOTE: This Acronyms and Definitions listing contains technical terms applicable to Ford Motor Company products. It is not intended to be an all-inclusive dictionary of components and their functions. If a detailed description of a particular system or component is desired, refer to the applicable Vehicle System for the specific vehicle being serviced. 2V: Two Valve engine configuration. 4V: Four Valve engine configuration. ABS: Anti-lock Brake System. A/C: Air Conditioning. A vehicle accessory system that modifies the passenger compartment air by cooling and dehydrating the air. ACC: Air Conditioning Clutch. Indicates status of the A/C clutch. ACCS: Air Conditioning Cycling Switch. Indicates status of the A/C cycling switch. ACD: Air Conditioning Demand. A signal input to the PCM from the Air Conditioning control panel. ACP: Air Conditioning Head Pressure or A/C cycling switch input state. ACPSW: Air Conditioning Pressure Switch. ACPV: Air Conditioning Head Pressure Volts. A voltage input to the Powertrain Control Module (PCM) from the ACP switch or sensor. ACR: Air Conditioning Relay. Commanded output controlled by the PCM and acts as an A/C cutout control during heavy acceleration. A/D: Analog-to-Digital. Analog-to-Digital signal conversion. ADC: See ATDC. AFCM: Alternative Fuel Control Module. AIR: Secondary Air Injection. AIRB: Secondary Air Injection Bypass. Air Diverter: Air Diverter Valve. Part of the EAIR system. Diverts fresh air to the exhaust system when the electric air pump is commanded on. AIR EVAL: Air System Evaluated. Displays a YES or NO status indicating whether the Air System has been evaluated for OBD (On-Board Diagnostic) II purposes. Air/Fuel Ratio: Air to fuel mixture ratio. An air/fuel mixture that is 14.7:1 is also called stoichiometry. AIRM: Secondary AIR pump monitor. Ambient Air Temperature: Temperature of the air surrounding an object. Analog (Electrical/Electronic): An electrical signal that can obtain any value within the voltage limits of the signal. ARB: Air Resource Board. ARPMIDES: Ancillary RPM Desired. RPM required to maintain the vehicle speed commanded by Speed Control Command Switch (SCCS) inputs. ASCII: American Standard Code for Information Interchange. ATDC: After Top Dead Center. The location of the piston after it has reached the top of its stroke. Measured in degrees of crankshaft rotation. AVOM: Analog Volt-Ohm Multimeter. Readings are indicated by a sweep hand on a printed scale, rather than a digital display. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Acronyms and Definitions > Page 4686 AWD: All-Wheel Drive. BARO: Barometric Pressure. Base Idle: Idle rpm determined by the throttle lever hardset on the throttle body with the IAC solenoid disconnected. Base Timing: Spark advance in degrees before top dead center of the base engine without any control from the PCM or ICM. Battery Positive Voltage (B+): The positive (+) voltage from the battery or any circuit connected directly to the battery. Compare "Vehicle Power (VPWR)." BAT TEMP: Battery Temperature. BJB: Battery Junction Box. BOB: Breakout Box. A test device which connects in series to the PCM and PCM harness. BPA: Brake Pedal Applied switch. Typically located on the braking system master cylinder. Can be hydraulic or electric. BPP: Brake Pedal Position. Indicates the position of the brake pedal, based on input from the Brake Pedal Position (BPP) switch. BRAKE LMP or BRKL: Brake Warning Lamp Status. Activates the Brake Warning Lamp by applying voltage to the control line. BTDC: Before Top Dead Center. The location of the piston before it has reached the top of its stroke. Measured in degrees of crankshaft rotation. Bus + or Bus -: Multiplex circuits that carry Standard Corporate Protocol (SCP) data from module to module and to the DLC. CAC: Charge Air Cooler. Formerly known as Intercooler. A device which lowers the temperature of pressurized intake air. CAFE: Corporate Average Fuel Economy. A set of federal requirements and regulations which govern fuel economy standards. CANVNT: Canister Vent Solenoid. Catalyst: Catalytic converter. An in-line exhaust system device used to reduce the level of engine exhaust emissions. CAT EVAL: Catalyst System Evaluated. This item indicates YES when the Catalyst Efficiency Monitor has successfully completed. CCM: Comprehensive Component Monitor. CCRM: Constant Control Relay Module. A relay module that provides ON-OFF control of various EEC components. CD A through J: Coil Driver 1 through 10. Centralized Testing Facility: State government operation. Provides Inspection/Maintenance (IM) and safety inspections. CGND or CSE GND: Case Ground. Provides a ground source for the PCM or ECU case. CHT: Cylinder Head Temperature. Units are displayed in either degrees Fahrenheit or Centigrade. CHTIL: Cylinder Head Temperature Indicator Lamp. CHTV: Cylinder Head Temperature Voltage. The actual voltage drop across the CHT sensor thermistor. CID: Cylinder Identification. PCM input signal from Camshaft Position Sensor. CKP: Crankshaft Position. Senses the position of the crankshaft. CKP+, CKP-: CKP+ is the Crankshaft Position (CKP) sensor signal wire. CKP - is the signal return. CL: Closed Loop. An operating condition or mode which enables operation based on sensor feedback. CMP: Camshaft Position. Indicates camshaft position. CMPFM: Camshaft Position Failure Mode. Indicates when the PCM identifies a CID/CMP fault. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Acronyms and Definitions > Page 4687 CMS: Catalyst Monitor Sensor. Downstream H025. CMVSS: Canadian Motor Vehicle Safety Standards. CNG: Compressed Natural Gas. CO: Carbon Monoxide. A colorless, odorless and toxic gas that is a component of auto exhaust emissions. CO(2): Carbon Dioxide. A colorless, odorless gas that is a normal by-product of the combustion of fuel. Coil: A device consisting of windings around an iron core. In a spark ignition system, designed to increase voltage. Cold Soak: Time given to a vehicle to sit at a low temperature (typically below 68°F / 20°C) until the temperature of external and internal components stabilize. CONT: Continuous Memory. The portion of KAM (Keep Alive Memory) used to store DTCs generated during Continuous Memory Self-Test. Continuous Memory Self- Test: A continuous test of the EEC system conducted by the PCM whenever the vehicle is operating. CPP: Clutch Pedal Position. Indicates clutch pedal position. CPP Switch: Clutch Pedal Position Switch. Located on the clutch pedal and detects when the clutch pedal is depressed. CQIS: Common Quality Indicator System. CSE GND: Case Ground. CT: Closed Throttle Mode. A mode when the PCM varies the pulse width of the fuel injectors to obtain the air/fuel mixture appropriate for closed throttle operation. CTO: Clean Tach Output. Signal used to drive the instrument panel tachometer. Data Communications Link: A communication path between various in-vehicle electronic modules. Accessed by scan tools through the Data Link Connector (DLC). DC: 1. Direct Current. Electric current flowing in one direction. 2. Duty Cycle. The voltage measurement of ON time versus the full cycle period, expressed in percent. DCL: Data Communication Link. DI: Distributor Ignition. A system in which the ignition coil secondary circuit is sequenced by a distributor. Digital: Controls process information by switching the current or voltage ON and OFF. DLC: Data Link Connector. J1962 connector providing access to vehicle diagnostic information. DOHC: Dual Overhead Cam. An engine configuration that uses two camshafts positioned above the valves. DOL: Data Output Line. A circuit that sends certain information from the PCM to the instrument cluster. DPFEGR: Differential Pressure Feedback Exhaust Gas Recirculation. System that uses a pressure transducer to control the operation of the Exhaust Gas Recirculation (EGR) Vacuum Regulator Valve. DRI: Deposit Resistant Injector. A fuel injector designed to prevent build-up of carbon and other unwanted deposits. DRL: Daytime Running Lamps. A system that keeps the vehicle running lamps on at all times while the vehicle is operating. DTM: Diagnostic Test Mode. A level of capability in an On-Board Diagnostic (OBD) system. DTC: Diagnostic Trouble Code. An alpha/numeric identifier for a fault condition identified by the On-Board Diagnostic System. DVOM: Digital Volt-Ohm Meter. E-85: Fuel containing 85% ethanol alcohol. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Acronyms and Definitions > Page 4688 EAIR: Electric Secondary Air Injection. A pump-driven system for providing secondary air using an electric air pump. EAIRM: Electric Secondary Air Pump circuit Monitor. ECT: Engine Coolant Temperature. Displayed in either Fahrenheit or Centigrade. ECTV: Engine Coolant Temperature Voltage. The actual voltage drop across the ECT sensor thermistor. ECU: Electronic Control Unit. A module that handles the control strategy and monitors system inputs or outputs. EEC: Electronic Engine Control system. EEC-V: Fifth generation EEC system. EFT: Engine Fuel Temperature. EFTA: Bank 1 input. EFTA is displayed in either Fahrenheit or Centigrade. EFTAV: Voltage drop across the EFTA (Bank 1) sensor thermistor. EFTB: Bank 2 input. EFTB is displayed in either Fahrenheit or Centigrade. EFTBV: Voltage drop across the EFTB (Bank 2) sensor thermistor. EGR: Exhaust Gas Recirculation. A process in which a small amount of exhaust gas is routed into the combustion chamber. EGR EVAL: Exhaust Gas Recirculation System Evaluated. EGR EVAL will display YES when the monitor is complete. EGRMDSD: Electric Exhaust Gas Recirculation Motor Desired position. The PID name used to operate the Electric Exhaust Gas Recirculation (EEGR) valve with scan tool's output state control. EGRS: EGR Shutoff. A normally closed solenoid that applies vacuum to the EGR valve when energized by the PCM. EGRT: Exhaust Gas Recirculation Valve Temperature Sensor. A temperature sensor that is threaded into the bottom of the intake plenum. EGR Vacuum Regulator: Controls vacuum to the EGR valve by a duty cycle signal from the PCM. EGRVR: Exhaust Gas Recirculation Vacuum Regulator. Solenoid which varies the vacuum to the EGR valve by varying the duty cycle to the regulator. EGRVRA: Exhaust Gas Recirculation Vacuum Regulator Actual (volt). The actual state of the commanded output. EGRVRF: Exhaust Gas Recirculation Vacuum Regulator Fault. Represents whether a fault exists in the EGRV circuit. EI: Integrated Electronic Ignition. An Electronic Ignition system that has the Ignition Control Module (ICM) integrated into the PCM. EI-HDR: Electronic Ignition, High Data Rate. Formerly known as Electronic Distributorless Ignition System. EI-LDR: Electronic Ignition, Low Data Rate. Formerly known as Distributorless Ignition System. EMI: Electromagnetic Interference. Usually caused by ignition voltage spikes, solenoids, relay operation or noisy generator contacts. EOL: End Of Line. A system designed specifically for use at assembly plants to make sure all new vehicles perform to design specifications. EPA: Environmental Protection Agency (U.S. Government). EPROM: Erasable Programmable Read-Only Memory. An electronic component in the PCM that requires the electronic storage of information. ESOF: Electronic Shift-on-the-Fly. EVAP: Evaporative Emissions. A system to prevent fuel vapor from escaping into the atmosphere. EVAPCP: Evaporative Canister Purge Solenoid. Controls a solenoid which allows venting of the evaporative purge canister. EVAPCPF: Evaporative Canister Purge Solenoid Fault. Identifies whether an electrical fault exists for the current commanded state. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Acronyms and Definitions > Page 4689 EVAPCV: Evaporative Canister Vent Solenoid. Controls a solenoid which seals the EVAP system canister from atmospheric pressure during the EVAP OBD II Monitor test. Evaporative Emissions Canister: An evaporative emission canister, containing activated charcoal which absorbs and holds fuel vapors. EVAPPDC: Evaporative Canister Purge Duty Cycle. The duty cycle commanded to the Evap Canister Purge Solenoid by the PCM. EVO: Electronic Variable Orifice. EWP: Electric Water Pump. Exciter Ring: A toothed or notched iron or steel disk, which is the moveable part of a wheel speed sensor. FAN: Fan Speed. Used in conjunction with vehicles having multiple fan speed control. Displays OFF, LOW, or HIGH status. FC: Fan Control. FCS: Fuel Control Solenoid. FCIL: Fuel Cap Off Indicator Lamp. Indicates that the fuel filler cap was not properly installed. FEAD: Front End Accessory Drive. FEPS: Flash Electrically Erasable Programmable Read Only Memory (EEPROM) Programming Signal. 18 volt DC signal sent by the scan tool to initiate PCM reprogramming. FF: 1. Flexible Fuel. A system capable of using a variety of fuels for vehicle operation. 2. A PID that displays the % alcohol content in fuel. FFLRN: Flex Fuel Learned. Displays when the PCM's Flex Fuel strategy has completed calculating the inferred alcohol content of fuel. FFFM: Flexible Fuel Failure Mode. Indicates whether the current Flex Fuel Sensor reading (FF) is reliable or not. Displays a YES or NO. FFTEMP: Flexible Fuel Sensor - Temperature. Alcohol concentration derived from the signal pulse width. FFV: Flexible Fuel Vehicle. FIFO: First In First Out. FILO: First In Last Out. FIM: Fuel Indicator Module. FLI: Fuel Level Input. Used by the Evap monitor to calculate fuel tank vapor volume. Displayed as a percentage. FLIV: Fuel Level Input Voltage. FMEM: Failure Mode Effects Management. Operating strategy that maintains limited vehicle function in the event of a PCM or EEC component failure. FP:1. Fuel Pump. Indicates whether the pump has been commanded ON or OFF by the PCM. 2. Fuel Pump (Modulated). Fuel pump duty cycle percentage. FPDM: Fuel Pump Driver Module. A module that controls the electric fuel pump. FPF: Fuel Pump Fault. Identifies whether a fault exists in the FP circuit. FPM: Fuel Pump Monitor. Monitors the Fuel Pump I circuits for faults. Freeze Frame: A block of memory containing the vehicle operating conditions at a specific time. FRP: Fuel Rail Pressure. Based on FRP V. FRP V: Fuel Rail Pressure Voltage. A voltage input to the PCM from the Fuel Rail Pressure Sensor. FSC: Fail-Safe Cooling. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Acronyms and Definitions > Page 4690 FSV: Fuel Shut-off Valve. A component of Natural Gas Vehicles. This valve either allows or prevents Natural Gas flow to the fuel rail. FSVF: Fuel Shut-Off Valve Fault. Indicates if there is a fault in the FSV circuit. Displayed as YES or NO. FSVM: Fuel Shut-off Valve Monitor. Monitors operation of the Fuel Shut-Off Valve / circuit. FTP: Fuel Tank Pressure. Displayed as inches of water, kPa, or volts. FTP V: Fuel Tank Pressure Voltage. From the FTP transducer. FUEL PR: Fuel Pressure. Measurement of the force of the fuel delivered via the fuel pump. FUELPW: Fuel Pulse Width. Displays the commanded pulse width at time of last data update. FUELPW1: Fuel Injector Pulse Width #1. Corresponds to injectors normally affected by O2S1 (HEGO1). FUELPW2: Fuel Injector Pulse Width #2. Corresponds to injectors normally affected by O2S2 (HEGO2). FUELSYS: Fuel System Status (OPEN/CLOSED Loop). Formerly known as LOOP. Fuel Tank Vapor Valve: A valve mounted in the top of the fuel tank that vents excess vapor and pressure from the fuel tank into the Evaporative Emission Control System. FWD: Front Wheel Drive. GEM: Generic Electronic Module. GEN: Generator. GENF: Generator Output Fault. GENFDC: Generator Field Control Output. GFS: Generator field signal monitor. GND: Ground. GPM: Grams Per Mile. Also known as Gallons Per Minute. GPS: Global Positioning Satellite. Green State Vehicle: Formally known as California Emissions. A vehicle that is equipped with California on-board diagnostics. GSS: Gear Select Solenoid. GVW: Gross Vehicle Weight. Hall Effect: A process where current is passed through a small slice of semi-conductor material and a magnetic field to produce a small voltage in the semi-conductor. Hard Fault: A fault currently present in the system. HC: 1. Hydrocarbon. A by-product of combustion and a component of auto exhaust emissions. 2. High Compression. HCF: Hydraulic Cooling Fan. HCFD: Hydraulic Cooling Fan Drive. HFC: Hydraulic Cooling Fan. HFCF: High Fan Control Fault. Identifies if there is a fault in the HFC circuit. HFP: High Fuel Pump. HLOS: Hardware Limited Operating Strategy. A mode of operation where the PCM replaces output commands with fixed values in response to internal Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Acronyms and Definitions > Page 4691 PCM malfunctions. HO: High Output. HO2S: Heated Oxygen Sensor. Formerly known as Heated Exhaust Gas Oxygen (HEGO) Sensor. Provides information on rich or lean exhaust conditions to the PCM. Hot Soak: Period of time after an engine operates where localized combustion heat dissipates throughout the engine. HTR, HTR11, HTR12, HTR21 H1R22, HTRX1, HTRX2: HO2S Heater. Heater element for the HO2S sensor. Hydrogen: Chemical symbol H. Highly flammable gas. Hz: Hertz. Cycles per second. IAC: Idle Air Control. Electrical control of throttle bypass air. IAT: Intake Air Temperature. IATV: Intake Air Temperature Voltage. Actual voltage drop across the IAT sensor. IAT2: Intake Air Temperature 2. Displayed in either Fahrenheit or Centigrade. Used on supercharged vehicles. IAT2V: Intake Air Temperature 2 Voltage. Actual voltage drop across the IATV2 sensor. IC: Integrated Circuit. A small Semi-Conductor device capable of doing many separate circuit functions. ICM: Ignition Control Module. The module that controls the ignition system. IFDM: Integrated Fuel Delivery Module. IFS: Inertia Fuel Shutoff. IGN GND: Ignition Ground. Ignition: System used to provide high voltage spark for internal combustion engines. IGNKEY(IGKY): Ignition Key status. IGNSW (IGSW): Ignition Switch Position. IMRC: Intake Manifold Runner Control. Controls airflow through the high-speed runners in the intake manifold. IMRCM: Intake Manifold Runner Control Monitor. Monitors the IMRC / circuits for faults. IMTV: Intake Manifold Tuning Valve. Controls airflow through runners in a split intake manifold. INJ1, INJ2, INJ3, INJ4, INJ5, INJ6, INJ7, INJ8, INJ9, INJ1O: lnjector number or its signal output from the PCM. Injector: A device for delivering metered pressurized fuel to the intake system or the cylinders. Intake Air: Air drawn through a filter and distributed to each cylinder for use in combustion. Intercooler: See CAC. IPATS: Integrated Passive Anti-Theft System. ISO: international Standards Organization. KAM: Keep Alive Memory. A portion of the memory within the PCM that must have power even when the vehicle is not operating. KAPWR: Keep Alive Power. Dedicated, unswitched power circuit that maintains KAM. Key On Engine Off Self- Test: A test of the EEC system conducted by the PCM with power applied and the engine at rest. Key On Engine Running Self- Test: A test of the EEC system conducted by the PCM with the engine running and the vehicle at rest. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Acronyms and Definitions > Page 4692 KEYPWR: Key Power. Battery voltage supplied when the ignition key is in the ON position. Knock: The sharp metallic sound produced when two combustion pressure fronts collide in the combustion chamber of an engine. KOEC: Key On Engine Continuous. KOEO: Key On Engine off. KOER: Key On Engine Running. KPA: Kilopascal. Unit of pressure. 3.386 kPa = 1 inch of mercury (Hg.). KPH: Kilometers Per Hour. KS: Knock Sensor. Detects engine knock. L: Liters. The unit of volume in the metric measuring system. One liter equals 1.06 quarts. LEV: Low Emissions Vehicle. LFC: Low Fan Control. LFP: Low Fuel Pump. Reduced operating speed for multi-speed fuel pumps. LIFO: Last In First Out. LILO: Last In Last Out. LONGFT1, LONGFT2: Long-Term Fuel Trim. Fuel flow adjustment determined by the PCM. LOOP: indicates OPEN or CLOSED loop status. LPG: Liquefied Petroleum Gas. LPLR: Low Pressure Low Resistance fuel injector. M-V ACRONYMS AND DEFINITIONS NOTE: This Acronyms and Definitions listing contains technical terms applicable to Ford Motor Company products. It is not intended to be an all-inclusive dictionary of components and their functions. If a detailed description of a particular system or component is desired, refer to the applicable Vehicle System for the specific vehicle being serviced. M-85: Fuel containing 85% methanol alcohol. MAF: Mass Air Flow. Used to measure the mass (weight) of the air entering the engine. MAF RTN: Mass Air Flow Return. A return circuit for the MAF sensor. MAP: Manifold Absolute Pressure. The internal pressure of the intake manifold. MFC: Medium Fan Control. MFI: Multiport Fuel Injection. A fuel-delivery system in which each cylinder is individually fueled. MFP: Modulated Fuel Pump. Microprocessor: A digital processor on a chip which perform arithmetic and control logic. MIL: Malfunction Indicator Lamp. An indicator lamp alerting the driver of an emission related malfunction. May also read "CHECK ENGINE" or "SERVICE ENGINE SOON." MISF: Misfire. Any event in the cylinder that causes a sudden change in acceleration of the crankshaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Acronyms and Definitions > Page 4693 MON: Motor Octane Number. Monolithic Substrate: The ceramic honeycomb structure used in the catalytic converter. MSOF: Manual Shift-on-the-Fly. MY: Model Year. NA: Naturally Aspirated. Engine that is not supercharged or turbocharged. NAAO: North American Automotive Operations. NC: Normally Closed. NG: Natural Gas. A system capable of using natural gas for vehicle operation. NGS: New Generation STAR (Self-Test Automatic Readout) tester. NGVM: Natural Gas Vehicle Module. NO: Norm ally Open. NO(x): Oxides of Nitrogen. Formed at high combustion temperatures. NVH: Noise, Vibration, Harshness. A classification of vehicle concerns. OASIS: On-Line Automotive Service Information System. OBD, OBD-II: On-Board Diagnostics, On-Board Diagnostics Second Generation. A system that monitors PCM input and output control signals. On Demand Test: Technician initiated "KOEO" and "KOER" tests performed by the PCM. OC: Oxidation Catalytic converter. A catalytic converter system that reduces levels of HC and CO. OCT ADJ: Octane Adjust. Compensating strategy that adjusts for changes in fuel octane. OEM: Original Equipment Manufacturer. OHC: OverHead Cam. An engine configuration that uses a single camshaft positioned above the valves. OWL: Overheat Warning Lamp or its signal output from the PCM. Turns the TEMP warning lamp ON when engine oil temperature exceeds safe limits. Open Circuit: A circuit which does not provide a complete path for flow of current. OL: Open Loop. An operating condition based on instructions not modified by PCM feedback. O(2)S 11/12/21/22: Oxygen Sensor and its relative position in the exhaust system. Detects oxygen content in exhaust gasses. OSC: Output State Control. OSS: Output Shaft Speed. Ozone: A blue gaseous form of oxygen (O(3)) formed naturally by electric discharge or exposure to ultraviolet radiation. Particulate: Small solid matter found in exhaust gases, especially prevalent in diesel engines. PATS: Passive Anti-Theft System. PATSIL: Passive Anti-Theft System Indicator Light. PATSIN: Passive Anti-Theft System Receive Signal. PATSOUT: Passive Anti-Theft System Transmit Signal. PATSTRT: Passive Anti-Theft System Starter Relay Control Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Acronyms and Definitions > Page 4694 PCM: Powertrain Control Module. Formerly known as the EEC (Electronic Engine Control) Processor. PCV: Positive Crankcase Ventilation. A system which allows the controlled flow of crankcase vapors into the combustion chamber. PF: Purge Flow. Amount of fuel vapor burned in the engine. Photochemical: Term describing the action of light on air pollutants which results in creating smog. PID: Parameter Identifier. Identifies an address in PCM memory which contains operating information. Powertrain: Engine and transmission/transaxle components. Pressure - Absolute: A pressure referenced to a perfect vacuum. Pressure - Atmospheric: The pressure of the surrounding air at any given temperature and altitude. Sometimes called Barometric Pressure. Pressure - Barometric: Pertaining to atmospheric pressure or the results obtained by a barometer. Pressure - Differential: The pressure difference between two regions, such as between the intake manifold and atmospheric pressure. Pressure - Gage: The amount by which absolute pressure exceeds the ambient atmospheric pressure. PIP: Profile Ignition Pickup. Provides crankshaft position information for ignition synchronization. Potentiometer: An adjustable resistance component commonly used as a sensor (Example: TP Sensor). PPM: Parts Per Million. A measure used in emission analysis. PROM: Programmable Read-Only Memory. Similar to ROM except without program instructions. Protocol: A set of rules for the exchange of information on a network. PSOM: Programmable Speedometer/Odometer Module. A module that processes vehicle speed information. PSP: Power Steering Pressure. Indicates the pressure in the power steering system. PSP V: Power Steering Pressure Input Voltage. PTEC: Powertrain Electronic Controller. PTO: Power Take-Off. PW: Pulse Width. The length of time an actuator, such as a fuel injector, remains energized. PWM: Pulse Width Modulation. Controls the intensity of an output by varying the signal duty cycle. PWR GND: Power Ground. The main ground circuit in the EEC system. Quick Test: A series of diagnostic tests of the EEC system consisting of KOEO, KOER and Continuous Memory Self-Tests. Results are displayed as a series of DTCs. RABS: Rear Antilock Brake System. RAM: Random Access Memory. Memory into which information can be written as well as read. REDOX: Reduction Oxidation Catalytic converter. A catalytic converter system designed to operate at high temperatures. Regulator: Controls the alternator/generator field current to maintain proper battery charge. Contained within the PCM in smart charging applications. Relay: An electromechanical device in which connections in one circuit are opened or closed by changes in another circuit. REM: Rear Electronic Module. Repetitive Spark: Multiple firings of individual spark plugs at engine speeds below 1000 RPM to improve idle quality and improve emissions. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Acronyms and Definitions > Page 4695 RF: Radio Frequency. RFI: Radio Frequency Interference. RFS: Returnless Fuel System. RM: Relay Module. A module containing two or more relays. ROM: Read-Only Memory. Computer memory that can be accessed and utilized, but not altered. RON: Research Octane Number. Routine: A group of related tasks, such as a series of diagnostic tests. RPM: Revolutions Per Minute. RS: Reverse Switch. RTN: Return. A dedicated sensor ground circuit. RWD: Rear Wheel Drive. SAE: Society of Automotive Engineers. SBS: Supercharger Bypass Solenoid or its signal output from the PCM. SC: Supercharged or Supercharger. SCB: Supercharger Bypass Control. A system that allows manifold vacuum to be bled away from the supercharger wastegate actuator to allow for maximum boost. SCBF: Supercharger Bypass Control Fault. Identifies whether a fault exists in the Supercharger Bypass circuit. SCICP: Supercharger Intercooler Pump Control. SCICPF: Supercharger Intercooler Pump Control Fault. SCIPC: The PID to monitor the operation of the Supercharger and Charge Air Cooler pump. SCP: Standard Corporate Protocol. Self- Test: See Quick Test. Sensor: A device that detects the value or change in a physical quantity, such as temperature, pressure or flow rate, and converts the data into an electrical signal. SFI: Sequential Multi port Fuel Injection. A multiport fuel delivery system where each injector is individually energized and timed relative to its cylinder intake event. Shield: A conducting sleeve that surrounds wires to be electronically isolated from Electromagnetic Interference (EMI). Short Circuit: An undesirable condition in a circuit where it is terminated at a point other than that intended. SHRT FT: Short-Term Fuel Trim. Fuel flow adjustment in response to the HO2S sensor(s) input during closed-loop operation. SIG RTN: Signal Return. A dedicated sensor ground circuit that is common to two or more sensors. SIL: Shift Indicator Lamp. Smart Driver: A PCM or ECU output driver that can detect faults (open or shorts) on its output circuit. SME: Society of Manufacturing Engineers. SOF: Shift-On-the-Fly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Acronyms and Definitions > Page 4696 SOHC: Single Overhead Cam. Solenoid: A device consisting of an electrical coil which produces a magnetic field in a plunger and pulled to a central position. ST: Scan Tool. A device that interfaces with and communicates information on a data link. Stoichiometry: An air/fuel mixture that is neither too rich nor too lean. Stoichiometric ratio is 14.7 parts of air for every 1 part of fuel. Switch: A device for making, breaking, or changing the connections in an electrical circuit. TA: Traction Assist. TACH: Tachometer. TB: Throttle Body. A device that controls airflow through the engine via a butterfly valve, and has an air bypass channel around the throttle plate. TC: 1. Traction Control. Combines anti-lock braking and axle torque reduction to control wheel slippage. 2. Turbocharger. TDC: Top Dead Center. Tear Tag: The two-piece adhesive label attached to the PCM to identify its calibration. Thermistor: A temperature dependent resistor, like that used in CHT and ECT sensors. Timing: Relationship between spark plug firing and piston position expressed in crankshaft degrees before (BTDC) or after (ATDC) top dead center of the compression stroke. TMAP: Thermal Manifold Absolute Pressure Sensor. A MAP Sensor that includes a thermistor to measure intake air temperature. TP: Throttle Position (sensor). A three-wire potentiometer that provides throttle angle and rate information for the PCM. TP V: Throttle Position Sensor Voltage. Transducer: A device that receives energy from one medium and transfers it to another. For example, thermal energy is converted to an electrical signal through a temperature probe. Transmissions/Transaxles: NOTE: All related items are grouped under the general heading "TRANSMISSIONS" located at the end. TSB: Technical Service Bulletin. Notifies service personnel of any known vehicle concerns, procedures, or general service information. Underspeed Mode: A control mode that prevents the engine from stalling in the event it stumbles while running. Also used during engine crank. Vacuum: Manifold pressure that is reduced below the ambient atmospheric pressure. Variable Reluctance: A process of passing a varying magnetic field through wire windings and inducing a voltage. VCT: Variable Camshaft Timing. VECI: Vehicle Emission Control Information label. VIN: Vehicle Identification Number. A unique identification number given to every vehicle produced. Includes information about the year, model, engine, and plant origin of the vehicle. VMV: Vapor Management Valve. Controls the flow of fuel vapors out of the carbon canister. VOM: Volt-Ohm Meter. Readings are indicated by sweep hand on a printed scale rather than a digital (DVOM) display. VPWR: Vehicle Power. A switched circuit that provides power to the EEC system. Compare "Battery Voltage VREF: Reference Voltage. A dedicated circuit that provides approximately a 5.0 volt signal used as a reference by certain sensors. WAC: Wide Open Throttle A/C Cut-off. Turns A/C system off during wide open throttle or certain other operating conditions. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Acronyms and Definitions > Page 4697 Wastegate Control: A device that opens the wastegate in case of overboost from a turbocharger. WOT: Wide Open Throttle. A condition of maximum airflow through the throttle body. Zip Tube: Another name for "fresh air duct" or "air inlet duct". TRANSMISSIONS: NOTE: The transmission naming convention is as follows: ^ The first character, a number, is the number of forward gears. ^ The second character, either the letter "F" or "R," represents front (transaxle) or rear (transmission) wheel drive. ^ The next set of characters, a grouping of numbers, represents the design torque capacity of the transmission/transaxle (for example, "27" represents 270ft./lbs. in the 4F27E transaxle). ^ The last character, if used, is one of the following: ^ "E" for electronic shift ^ "N" for non-synchronous shift ^ "S" for synchronous shift ^ "W" for wide ratio ^ 4F27E: Also known as the FN Focus automatic transmission. ^ 4F44E: Formerly known as the CD4E. ^ 4F46S: Formerly known as the Ax45 and regular-duty AXOD-E. ^ 4F50N: Formerly known as the Ax4N and heavy-duty AXOD-E. ^ 4R44E: Formerly known as A4LD for 3.0L applications. ^ 4R55E: Formerly known as A4LD for 4.0L applications. ^ 4R70W: Formerly known as AOD-E. ^ 4R100: Formerly known as E4OD. ^ 5R44E: Formerly known as A5LD for 3.0L applications. ^ 5R55E: Formerly known as A5LD for 4.0L applications. ^ 5R55N: Lincoln LS automatic transmission. ^ 5R55W: Wide-ratio truck transmission. ^ 4x4L: 4x4 Low. ^ A/T: Automatic Transmission. ^ CCS: Coast Clutch Solenoid. ^ CCSF: Coast Clutch Solenoid Fault. Displays a YES if fault exists. ^ EPC: Electronic Pressure Control. ^ EPCV: Electronic Pressure Control Volts. ^ ESS: Electronic Shift Scheduling. ^ HCDSS: High Clutch Drum Speed Sensor. PCM input from the 4R44E and 4R55E. ^ M5OD: Manual 5-Speed transmission with overdrive (RWD). ^ M/T: Manual Transmission/Transaxle. ^ NPS: Neutral Pressure Switch or its signal input to the PCM. ^ OCS: Overdrive Cancel Switch. ^ OSS: Output Shaft Speed. Indicates rotational speed of the transmission output shaft. ^ PNP: Park/Neutral Position switch. Also known as Neutral Drive Switch (NDS), Neutral Gear Switch (NGS), and Transmission Switch Neutral (TSN). ^ REVERSE or REV: Transmission Reverse Switch Input. ^ SIL: Shift Indicator Lamp. A lamp that indicates the preferred shift points on select manual transmission/transaxle vehicles. ^ S91/SS2/SS3: Shift solenoids. Devices that control the shifting in an automatic transmission. ^ TCC: Torque Converter Clutch. When energized, causes a mechanical engagement and disengagement of the Torque Converter Clutch. ^ TCIL: Transmission Control Indicator Lamp. Indicates that the Transmission Control Switch (TCS) has been activated. ^ TCS: Transmission Control Switch. Modifies the operation of electronically controlled transmissions. ^ Torque converter: A device which by its design multiplies the torque in a fluid coupling between an engine and transmission/transaxle. ^ TFT: Transmission Fluid Temperature. Indicates temperature of transmission fluid. ^ Transaxle: A device consisting of a transmission and axle drive gears assembled in the same case. Front-wheel drive applications. ^ Transmission: A device which selectively increases or decreases the ratio of relative rotation between its input and output shafts. Rear-wheel drive applications. ^ TR: Transmission Range. The range in which the transmission is operating. ^ TR Sensor: Formerly known as Manual Lever Position Sensor (MLPS). Provides information to the PCM on the transmission range selector position. ^ TR V: Transmission Range Voltage. ^ TSS: Turbine Shaft Speed. Indicates rotational speed of the transmission turbine shaft. ^ VSS: Vehicle Speed Sensor. A magnetic pickup device that generates an AC signal that is proportional to vehicle speed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Acronyms and Definitions > Page 4698 Positive Crankcase Ventilation: Description and Operation Positive Crankcase Ventilation System Positive Crankcase Ventilation System Overview The Positive Crankcase Ventilation (PCV) System (Figure 132) cycles crankcase gases back through the engine where they are burned. 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. The PCV valve should be mounted in a vertical position. On some applications, the PCV system is connected to the evaporative emission system (refer to the VECI decal). CAUTION: Do not remove the PCV system from the engine. Removal of the PCV system will adversely affect the fuel economy and engine ventilation and result in shorter engine life. PCV System HARDWARE PCV Internal Drawing Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Acronyms and Definitions > Page 4699 Typical PCV Vacuum Connector Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Page 4700 Positive Crankcase Ventilation: Testing and Inspection For information regarding diagnosis of this system refer to Computers and Control Systems Diagnosis. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control Systems > Air Injection Pump Relay > Component Information > Description and Operation Air Injection Pump Relay: Description and Operation SOLID STATE RELAY Solid State Relay The solid state relay (Figure 124) switches the high current required for operation of the electric AIR pump. Input control to the solid state relay comes from the Powertrain Control Module (PCM). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of 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). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4714 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4715 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4716 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4717 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4718 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect Technical Service Bulletin # 02M01S6 Date: 040831 Attachment I - Administrative Information Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. Note: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program. Vehicles within New Vehicle Warranty Coverage Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) Claims are to be submitted following program 02M01 guidelines. Future Warranty Extension Customer Satisfaction Programs (CSP) Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of 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). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor Allowances and Parts Ordering Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4724 LABOR ALLOWANCES [NEW] NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes: ^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03. ^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. ^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. ^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. ^ There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS/ORDERING INFORMATION NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4725 DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: ^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED ^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED ^ P0401- EGR FLOW INSUFFICIENT DETECTED ^ P0402- EGR FLOW EXCESSIVE DETECTED Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: a) Key off. b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4726 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4727 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4728 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4733 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4734 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4735 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL ON/Driveability Issues/DTC's Set Article No. 04-11-1 06/08/2004 DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001 EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC, EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER LINCOLN: 2001-2002 TOWN CAR MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003 MOUNTAINEER This article supersedes TSB 04-3-1 to update service part information and applications. ISSUE Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1). ACTION For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED Manual for the issue described above. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4741 NOTE ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA NOTE THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT THE FOLLOWING: ^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002 ^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002 ^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002 ^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003 SERVICE PROCEDURE 1. Retrieve continuous DTC(s). 2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor. 3. Clear continuous DTC(s). 4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4742 Labor Operations Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage. DEALER CODING CONDITION BASIC PART NO. CODE 9J460 42 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4743 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 4744 Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR Bolts 8 - 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 4745 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 4746 Pressure Feedback Exhaust Sensor: Description and Operation DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure transducer that monitors the differential pressure across a metering orifice located in the orifice tube assembly. The differential pressure feedback sensor receives this signal through two hoses referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 4747 Tube Mounted Differential Pressure Feedback EGR Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 4748 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the differential pressure feedback EGR electrical connector. 3. Disconnect the differential pressure feedback EGR hoses. 4. Remove the bolts and the differential pressure feedback EGR. INSTALLATION 1. Fit the differential pressure feedback EGR and loosely install the bolts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 4749 2. Tighten the bolts. 3. Connect the differential pressure feedback EGR hoses. 4. Connect the differential pressure feedback EGR electrical connector. 5. Connect the battery ground cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Fuel Pressure Relief Valve Bolts 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information Fuel Pressure Test Port: Technician Safety Information WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information > Page 4757 Fuel Pressure Test Port: Vehicle Damage Warnings CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 4758 Fuel Pressure Test Port: Description and Operation PRESSURE TEST POINT There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE TEST KIT #134-ROO87 OR EQUIVALENT. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 4759 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Remove the upper intake manifold. For additional information, refer to Engine. 2. Disconnect fuel supply line. 3. Remove the four bolts and the fuel supply line from the fuel supply manifold. 4. Remove the fuel supply line bracket bolt and the fuel supply line. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. NOTE: Lubricate the new O-ring seals with Super Premium SAE 5W-30 Motor Oil, XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G, to aid installation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR 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. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Page 4763 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL SERVICE TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR 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. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and attach the Fuel Pressure Gauge. 2. Open the manual valve on the Fuel Pressure Gauge slowly and relieve the fuel pressure. NOTE: Open the manual valve slowly to relieve the system pressure. This may drain fuel from the system. Place the fuel in a suitable container. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Page 4764 Fuel Pressure Gauge Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > With 104 Pin Processor Idle Speed: Specifications With 104 Pin Processor Hot Idle ................................................................................................................................................ ......................................................... 670 - 750 RPM Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > With 104 Pin Processor > Page 4769 Idle Speed: Specifications With 150 Pin Processor With Automatic Transmission Hot Idle ................................................................................................................................................ .................................................................. 750 RPM With Manual Transmission Hot Idle ................................................................................................................................................ .................................................................. 750 RPM Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications Accelerator Pedal: Specifications Accelerator Pedal And Shaft Pivot Screw 9 - 12 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 4773 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 4774 Accelerator Pedal: Description and Operation The accelerator cable is controlled by an accelerator pedal and shaft. The pedal and shaft should travel smoothly from the idle to wide-open throttle positions. Failure to return or hesitation on return to the idle position must not occur. Surrounding components such as wiring, hoses, sound insulator and floor covering must not contact the sliding inner member of the accelerator cable or the accelerator pedal and shaft. The speed control speedometer cable and the accelerator cable are attached at the throttle lever on the throttle body. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Accelerator Pedal: Initial Inspection and Diagnostic Overview NOTE: Care should be exercised when performing service on or around the accelerator pedal linkage and controls. 1. Inspect the accelerator pedal and shaft and attaching linkage for damage or distortion which would bind or limit accelerator travel. 2. Inspect the accelerator cable for kinks or fraying which may cause bending. 3. Inspect the engine idle speed adjustment to make sure of the correct idle speed specification after any accelerator linkage adjustment or repair. 4. Inspect throttle body for excessive wear or damage. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4777 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Cable Accelerator Pedal: Service and Repair Cable REMOVAL 1. Remove the screws and the accelerator control splash shield. 2. Disconnect the accelerator cable from the throttle body. 3. Disconnect the accelerator cable from the intake manifold. 1 Remove the screw. 2 Disconnect the accelerator cable from the intake manifold. 4. From inside the vehicle, disconnect the accelerator cable from the accelerator pedal and shaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Cable > Page 4780 5. Collapse the clips at the dash panel and push the accelerator cable through the dash panel into the engine compartment and remove the accelerator cable. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Cable > Page 4781 Accelerator Pedal: Service and Repair Pedal REMOVAL 1. Disconnect the accelerator cable from the accelerator pedal and shaft. See: Cable 2. Remove the accelerator pedal and shaft pivot screw, and remove the accelerator pedal and shaft. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Component Information > Service and Repair Air Cleaner Housing: Service and Repair REMOVAL 1. Disconnect the air cleaner assembly. ^ Loosen the clamp and disconnect the outlet tube. ^ Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the air cleaner assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications Mass Air Flow Sensor: Specifications Mass Air Flow Sensor Nuts And Bolts 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4788 Mass Air Flow Sensor: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4789 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4790 Mass Air Flow Sensor: Description and Operation MASS AIR FLOW SENSOR Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4791 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Loosen the air cleaner outlet tube clamp and position aside. 4. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle Technical Service Bulletin # 03-3-5 Date: 030217 Engine Controls - No Start/Hard Start/Rough Idle Article No. 03-3-5 02/17/03 DRIVEABILITY - IDLE AIR CONTROL (IAC) VALVE DIAGNOSTIC SERVICE TIPS FORD: 2000-2003 TAURUS 2002 THUNDERBIRD 2000-2003 EXPLORER, RANGER 2001-2003 EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 2000-2002 LS MERCURY: 2000-2003 SABLE, MOUNTAINEER ISSUE Some vehicles, may exhibit drivability conditions. These may include: ^ No start Difficult to start Stall ^ Low idle ^ Rough idle ^ High idle ^ Hesitation/surge while accelerating or at steady speed These conditions may be intermittent with no Diagnostic Trouble Codes (DTC) and no Malfunction Indicator Lamp (MIL). In some cases DTC and MIL may be evident. ACTION Trouble cannot be identified with 95% of returned Idle Air Control (IAC) valves. The following procedure is supplemental information to normal diagnostics to facilitate accurate identification of malfunctioning valves. These symptoms would include engine stall, hard start, crank/no start, idling problems, and Idle Speed Control System related DTC's. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4800 If the service writer uses the worksheet (Figure 2) for all drivability concerns including stalls it will assist the technician making a correct repair the first time. Perform normal diagnostics. SERVICE INFORMATION NOTE Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4801 IT MAY NOT BE POSSIBLE TO DUPLICATE THE CUSTOMER CONCERN. ALTHOUGH THE CONDITION MAY NOT BE DUPLICATED, IT IS RECOMMENDED THAT ANY EVALUATION OF THE IAC VALVE BE DONE IN ACCORDANCE WITH THE FOLLOWING SERVICE PROCEDURE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 602300 603300, 607000, 607400, 607700, 608000, 608400, 611000, 618400, 619400, 698298 Disclaimer IAC Diagnostic Service Tips - General Never clean an IAC valve. Carburetor cleaners and other cleaning agents may temporarily repair the drivability concern, but the long-term functionality of the valve is compromised. For all drivability concerns, make certain the service writer obtains as much information as possible from the customer as to the conditions causing drivability concern. Attached is a drivability concern check off sheet (Figure 2) that if used, can help reduce the time required to diagnose a vehicle. NOTE IF THE ENGINE STALLED WHILE THE VEHICLE WAS IN GEAR AND MOVING THE POSSIBILITY OF THE IAC VALVE CAUSING THIS IS UNLIKELY UNLESS IT OCCURRED ON DECELERATION. Use the following Supplemental information for 3.0L 4V Duratec Engines, in the Taurus/Sable, and Lincoln LS. 1. Use the following conditions for the test described below: ^ Transmission in park ^ Engine temperature should be at least 190° F (88°C) ^ All accessories should be off steering wheel in the center position ^ EGVR and EVAPDUTY CYCLE at zero, if the vehicle has an EGR system ^ Short and long term fuel trims less than 15% ^ At stabilized engine speed (RPM) and temperature (hot idle) per the Powertrain Control Emission Diagnostics (PC/ED) manual, verify the IAC duty cycle is within reference values called out in the chart in this TSB. NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure that there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. Use the following Supplemental Information for the 3.9L Lincoln LS and Thunderbird. 1. Use the following conditions for the test described below: ^ Transmission in park Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4802 ^ Engine idle at approximately 650 RPM ^ Engine temperature should be at least 190° F (88° C) ^ All accessories and the engine cooling fan should be off ^ Steering wheel in the center position ^ EGRVR and EVAPDUTY CYCLE are zero ^ Short and long term fuel trims less than 15% NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. NOTE IT IS EXTREMELY IMPORTANT TO CHECK THE IAC DUTY CYCLE WHEN THE RPM IS AT 650 RPM. EVEN 700 RPM IS TOO HIGH FOR CHECKING the IAC VALVE DUTY CYCLE UNDER THESE CONDITIONS. IF THE RPM IS OVER 650 RPM, MOMENTARILY OPENING AND CLOSING THE THROTTLE AND A SHORT EQUILIBRATION TIME WILL LOWER THE RPM. At stabilized engine speed and temperature, verify that the IAC duty cycle is between 27-36% with no purge flow (EVAPV duty cycle is 0%). If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. NOTE IF THE ORIGINAL IAC VALVE WAS WITHIN DUTY CYCLE SPECIFICATION OR THE DUTY CYCLE REMAINS OUT OF SPECIFICATIONS AFTER IAC VALVE REPLACEMENT FURTHER DIAGNOSTICS ARE REQUIRED TO ADDRESS THE CUSTOMER CONCERN. Use the following Supplemental Information for 4.0L SOHC Engines In the Ranger, Explorer, Mountaineer, Explorer Sport and Explorer Sport Trac. If no DTC's present check the following items in this order before examining the IAC valve: ^ BARO Hz reading - Refer to Barometric Pressure Chart listed in this TSB ^ Battery and fuse box power lead ^ Ground wire attachments ^ Wiring (wiggle test) ^ PCM voltage ^ Vacuum leaks Examine AC valve under these conditions: ^ PCM updated to the latest available calibration ^ Transmission in park ^ Warm stabilized vehicle with engine temperature at least 190° F (88° C) ^ All accessories and cooling fan sh6uld be off Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4803 ^ Steering wheel in the center position ^ EGVR and EVAPDC at zero, if the vehicle has an EGR system ^ Short and long term fuel trims (less than 15) Perform the following steps in order: 1. Using either NGS or WDS bring up the following PIDS: IACTRIM, IACKAM2, IACKAM3. 2. Allow vehicle to idle until the IACTRIM PID is 0. NOTE IACTRIM ALWAYS TRIES TO GO TO 0. WHEN MOVING TOWARDS 0, THE IACKAM2 PID SHOULD BE CHANGING. IF IACKAM3 IS CHANGING, THEN THE AIR CONDITIONING SHOULD BE TURNED OFF. 3. If IACKAM2 is between -0.35 and +0.35 with IACTRIM=0, then the valve is operating properly at idle. The remainder of this TSB will help diagnose true root cause. 4. If IACKAM2 is not between -0.35 and +0.35, it is highly likely that the engine idle system (to include the throttle body and air intake system) -is not operating properly. NOTE FOR ALL VEHICLES PLEASE RECORD THE OBSERVED IAC DUTY CYCLE AND ENGINE RPM IN THE WARRANTY CLAIMS COMMENTS FOR THIS DIAGNOSTIC. IAC Diagnostic Service Tips - DTC 1506 (IAC Over Speed Error) and other High Idle Concerns: ^ There are two primary causes of high idle: 1. Damaged IAC valves and 2. Vacuum leaks ^ AC valves can be damaged from engine induction backfires. Many times the customer may not notice the induction backfire but will notice the high idle afterwards. Indications of valve damage can be a shiny, almost polished appearance in the interior of the valve and a dislocated Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4804 pintle. An IAC valve damaged by backfire should be replaced. Refer to Figure 1. ^ Inspect PCV system for leaks especially looking for cracks along any rubber elbow joints; also verify that the correct PCV valve is installed. ^ Inspect for vacuum hoses loose or disconnected from intended ports and connections. Induction backfire can loosen or disconnect vacuum hoses. ^ Two indicators can help you identify if a vacuum leak is present, even if the engine RPM appear normal in the service bay. If the duty cycle is below specification that is indicative that the engine is receiving too much air (from a vacuum leak) and the PCM is ordering the valve to close up to restrict flow. Another indication is fuel trim. Record the long term and short term fuel trim PIDS (LONGFT1, LONGFT2, SHORTFT1, etc.), if short term fuel trims are high (above specification) this is a possible indication of a vacuum leak, making the engine run lean, and the PCM is attempting to compensate. IAC Diagnostic Service Tips - DTC 1507 (IAC Under Speed Error) and Other Low Idle Concerns: ^ An under speed error may not necessarily be a fault with the IAC valve. A large friction load on the engine or obstruction in the air intake system could also reduce the engine RPMs. ^ There are four possible sources of friction load that can contribute to under speed error or low idle concerns. 1. Power Steering Load 2. Air Conditioning Load 3. Electrical Load 4. Automatic Transmission Torque Converter Load EAC Diagnostic Service Tips - Rough Idle Concerns: ^ Rough idle concerns are often a result of a lean running condition ^ Another possible cause is contamination build up on the MAF sensor EAC Diagnostic Service Tips - Engine Hard Start/Engine Crank-No Start ^ While performing diagnostics, the technician should ensure that the fuel system is working correctly for all engines with hard start/crank no-start complaints. ^ When diagnosing a mechanical return less fuel system, the following correction to the PC/ED pinpoint HC (4) diagnostic procedure should be used when performing the KEOE fuel pressure test: ^ Perform the KOEO fuel pressure test as specific in the PC/ED manual. ^ The fuel pressure should drop off no more than 10 psi from maximum pressure (no lower than 55 psi for a 65 psi max system or no lower than 45 psi for a 55 psi max system) within 5 minutes of the start of the test. ^ The fuel pressure should drop off to no less than 30 psi within 30 minutes of the start of the test. ^ For greatest accuracy, the service technician should read the fuel pressure as soon as possible after pump shut off, no more than 5 minutes after the start of the test. NOTE RETURNABLE AND ELECTRONIC RETURN LESS SYSTEMS SHOULD ALSO BE DIAGNOSED USING THE PROCEDURES LISTED FOR THEM IN PINPOINT TEST HC. IAC Diagnostic Service Tips - High Idle RPM at Start Up: ^ Most engines will have a temporary high idle at engine start up to allow for catalyst light off. If DTC 1506 is not present, this indicates that there is no fault present with the IAC. ^ A vehicle with very low odometer miles, may exhibit a higher than normal temporary startup fast idle (1600-2500 RPM that decreases slowly). No Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4805 repairs should be attempted because this is a normal temporary PCM calibration strategy to prevent spark plug fouling during plant/transportation operation. The calibration will permanently revert to its normal strategy after the PCM has seen its first 4 miles of continuous drive cycle. A brand new vehicle may accumulate some mileage without turning this strategy off if the drive cycle has been below 4 miles at a time. IAC Diagnostic Service Tips - EAC Valve Noise Issues For IAC valve noise concerns check for obstructed or potentially damaged IAC valve from backfire. NOTE Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4806 ON SOME NEWER MODEL YEAR VEHICLES THE REACTION SPEED OF THE EAC VALVE IS FAST ENOUGH THAT IT MIGHT MAKE A "POPPING" SOUND AS IT REACTS TO A LARGE IDLE LOAD. THIS IS A NORMAL CHARACTERISTIC AND NO ATTEMPTS SHOULD BE MADE IN AN EFFORT TO MODIFY THE PERFORMANCE OF THE IAC VALVE. IF POSSIBLE, COMPARE AGAINST A LIKE VEHICLE. 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. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle Technical Service Bulletin # 03-3-5 Date: 030217 Engine Controls - No Start/Hard Start/Rough Idle Article No. 03-3-5 02/17/03 DRIVEABILITY - IDLE AIR CONTROL (IAC) VALVE DIAGNOSTIC SERVICE TIPS FORD: 2000-2003 TAURUS 2002 THUNDERBIRD 2000-2003 EXPLORER, RANGER 2001-2003 EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 2000-2002 LS MERCURY: 2000-2003 SABLE, MOUNTAINEER ISSUE Some vehicles, may exhibit drivability conditions. These may include: ^ No start Difficult to start Stall ^ Low idle ^ Rough idle ^ High idle ^ Hesitation/surge while accelerating or at steady speed These conditions may be intermittent with no Diagnostic Trouble Codes (DTC) and no Malfunction Indicator Lamp (MIL). In some cases DTC and MIL may be evident. ACTION Trouble cannot be identified with 95% of returned Idle Air Control (IAC) valves. The following procedure is supplemental information to normal diagnostics to facilitate accurate identification of malfunctioning valves. These symptoms would include engine stall, hard start, crank/no start, idling problems, and Idle Speed Control System related DTC's. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4812 If the service writer uses the worksheet (Figure 2) for all drivability concerns including stalls it will assist the technician making a correct repair the first time. Perform normal diagnostics. SERVICE INFORMATION NOTE Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4813 IT MAY NOT BE POSSIBLE TO DUPLICATE THE CUSTOMER CONCERN. ALTHOUGH THE CONDITION MAY NOT BE DUPLICATED, IT IS RECOMMENDED THAT ANY EVALUATION OF THE IAC VALVE BE DONE IN ACCORDANCE WITH THE FOLLOWING SERVICE PROCEDURE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 602300 603300, 607000, 607400, 607700, 608000, 608400, 611000, 618400, 619400, 698298 Disclaimer IAC Diagnostic Service Tips - General Never clean an IAC valve. Carburetor cleaners and other cleaning agents may temporarily repair the drivability concern, but the long-term functionality of the valve is compromised. For all drivability concerns, make certain the service writer obtains as much information as possible from the customer as to the conditions causing drivability concern. Attached is a drivability concern check off sheet (Figure 2) that if used, can help reduce the time required to diagnose a vehicle. NOTE IF THE ENGINE STALLED WHILE THE VEHICLE WAS IN GEAR AND MOVING THE POSSIBILITY OF THE IAC VALVE CAUSING THIS IS UNLIKELY UNLESS IT OCCURRED ON DECELERATION. Use the following Supplemental information for 3.0L 4V Duratec Engines, in the Taurus/Sable, and Lincoln LS. 1. Use the following conditions for the test described below: ^ Transmission in park ^ Engine temperature should be at least 190° F (88°C) ^ All accessories should be off steering wheel in the center position ^ EGVR and EVAPDUTY CYCLE at zero, if the vehicle has an EGR system ^ Short and long term fuel trims less than 15% ^ At stabilized engine speed (RPM) and temperature (hot idle) per the Powertrain Control Emission Diagnostics (PC/ED) manual, verify the IAC duty cycle is within reference values called out in the chart in this TSB. NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure that there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. Use the following Supplemental Information for the 3.9L Lincoln LS and Thunderbird. 1. Use the following conditions for the test described below: ^ Transmission in park Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4814 ^ Engine idle at approximately 650 RPM ^ Engine temperature should be at least 190° F (88° C) ^ All accessories and the engine cooling fan should be off ^ Steering wheel in the center position ^ EGRVR and EVAPDUTY CYCLE are zero ^ Short and long term fuel trims less than 15% NOTE IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES. NOTE IT IS EXTREMELY IMPORTANT TO CHECK THE IAC DUTY CYCLE WHEN THE RPM IS AT 650 RPM. EVEN 700 RPM IS TOO HIGH FOR CHECKING the IAC VALVE DUTY CYCLE UNDER THESE CONDITIONS. IF THE RPM IS OVER 650 RPM, MOMENTARILY OPENING AND CLOSING THE THROTTLE AND A SHORT EQUILIBRATION TIME WILL LOWER THE RPM. At stabilized engine speed and temperature, verify that the IAC duty cycle is between 27-36% with no purge flow (EVAPV duty cycle is 0%). If the Duty Cycle is out of specification, proceed with the following steps: 1. Ensure there is no purge flow. 2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is running and observe the IAC duty cycle and engine performance. Should abnormalities be observed, repair the harness as required. 3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times. If the duty cycle remains high, replace IAC valve. 4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC diagnostic service tip for DTC 1506 and other high idle concerns. NOTE IF THE ORIGINAL IAC VALVE WAS WITHIN DUTY CYCLE SPECIFICATION OR THE DUTY CYCLE REMAINS OUT OF SPECIFICATIONS AFTER IAC VALVE REPLACEMENT FURTHER DIAGNOSTICS ARE REQUIRED TO ADDRESS THE CUSTOMER CONCERN. Use the following Supplemental Information for 4.0L SOHC Engines In the Ranger, Explorer, Mountaineer, Explorer Sport and Explorer Sport Trac. If no DTC's present check the following items in this order before examining the IAC valve: ^ BARO Hz reading - Refer to Barometric Pressure Chart listed in this TSB ^ Battery and fuse box power lead ^ Ground wire attachments ^ Wiring (wiggle test) ^ PCM voltage ^ Vacuum leaks Examine AC valve under these conditions: ^ PCM updated to the latest available calibration ^ Transmission in park ^ Warm stabilized vehicle with engine temperature at least 190° F (88° C) ^ All accessories and cooling fan sh6uld be off Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4815 ^ Steering wheel in the center position ^ EGVR and EVAPDC at zero, if the vehicle has an EGR system ^ Short and long term fuel trims (less than 15) Perform the following steps in order: 1. Using either NGS or WDS bring up the following PIDS: IACTRIM, IACKAM2, IACKAM3. 2. Allow vehicle to idle until the IACTRIM PID is 0. NOTE IACTRIM ALWAYS TRIES TO GO TO 0. WHEN MOVING TOWARDS 0, THE IACKAM2 PID SHOULD BE CHANGING. IF IACKAM3 IS CHANGING, THEN THE AIR CONDITIONING SHOULD BE TURNED OFF. 3. If IACKAM2 is between -0.35 and +0.35 with IACTRIM=0, then the valve is operating properly at idle. The remainder of this TSB will help diagnose true root cause. 4. If IACKAM2 is not between -0.35 and +0.35, it is highly likely that the engine idle system (to include the throttle body and air intake system) -is not operating properly. NOTE FOR ALL VEHICLES PLEASE RECORD THE OBSERVED IAC DUTY CYCLE AND ENGINE RPM IN THE WARRANTY CLAIMS COMMENTS FOR THIS DIAGNOSTIC. IAC Diagnostic Service Tips - DTC 1506 (IAC Over Speed Error) and other High Idle Concerns: ^ There are two primary causes of high idle: 1. Damaged IAC valves and 2. Vacuum leaks ^ AC valves can be damaged from engine induction backfires. Many times the customer may not notice the induction backfire but will notice the high idle afterwards. Indications of valve damage can be a shiny, almost polished appearance in the interior of the valve and a dislocated Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4816 pintle. An IAC valve damaged by backfire should be replaced. Refer to Figure 1. ^ Inspect PCV system for leaks especially looking for cracks along any rubber elbow joints; also verify that the correct PCV valve is installed. ^ Inspect for vacuum hoses loose or disconnected from intended ports and connections. Induction backfire can loosen or disconnect vacuum hoses. ^ Two indicators can help you identify if a vacuum leak is present, even if the engine RPM appear normal in the service bay. If the duty cycle is below specification that is indicative that the engine is receiving too much air (from a vacuum leak) and the PCM is ordering the valve to close up to restrict flow. Another indication is fuel trim. Record the long term and short term fuel trim PIDS (LONGFT1, LONGFT2, SHORTFT1, etc.), if short term fuel trims are high (above specification) this is a possible indication of a vacuum leak, making the engine run lean, and the PCM is attempting to compensate. IAC Diagnostic Service Tips - DTC 1507 (IAC Under Speed Error) and Other Low Idle Concerns: ^ An under speed error may not necessarily be a fault with the IAC valve. A large friction load on the engine or obstruction in the air intake system could also reduce the engine RPMs. ^ There are four possible sources of friction load that can contribute to under speed error or low idle concerns. 1. Power Steering Load 2. Air Conditioning Load 3. Electrical Load 4. Automatic Transmission Torque Converter Load EAC Diagnostic Service Tips - Rough Idle Concerns: ^ Rough idle concerns are often a result of a lean running condition ^ Another possible cause is contamination build up on the MAF sensor EAC Diagnostic Service Tips - Engine Hard Start/Engine Crank-No Start ^ While performing diagnostics, the technician should ensure that the fuel system is working correctly for all engines with hard start/crank no-start complaints. ^ When diagnosing a mechanical return less fuel system, the following correction to the PC/ED pinpoint HC (4) diagnostic procedure should be used when performing the KEOE fuel pressure test: ^ Perform the KOEO fuel pressure test as specific in the PC/ED manual. ^ The fuel pressure should drop off no more than 10 psi from maximum pressure (no lower than 55 psi for a 65 psi max system or no lower than 45 psi for a 55 psi max system) within 5 minutes of the start of the test. ^ The fuel pressure should drop off to no less than 30 psi within 30 minutes of the start of the test. ^ For greatest accuracy, the service technician should read the fuel pressure as soon as possible after pump shut off, no more than 5 minutes after the start of the test. NOTE RETURNABLE AND ELECTRONIC RETURN LESS SYSTEMS SHOULD ALSO BE DIAGNOSED USING THE PROCEDURES LISTED FOR THEM IN PINPOINT TEST HC. IAC Diagnostic Service Tips - High Idle RPM at Start Up: ^ Most engines will have a temporary high idle at engine start up to allow for catalyst light off. If DTC 1506 is not present, this indicates that there is no fault present with the IAC. ^ A vehicle with very low odometer miles, may exhibit a higher than normal temporary startup fast idle (1600-2500 RPM that decreases slowly). No Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4817 repairs should be attempted because this is a normal temporary PCM calibration strategy to prevent spark plug fouling during plant/transportation operation. The calibration will permanently revert to its normal strategy after the PCM has seen its first 4 miles of continuous drive cycle. A brand new vehicle may accumulate some mileage without turning this strategy off if the drive cycle has been below 4 miles at a time. IAC Diagnostic Service Tips - EAC Valve Noise Issues For IAC valve noise concerns check for obstructed or potentially damaged IAC valve from backfire. NOTE Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4818 ON SOME NEWER MODEL YEAR VEHICLES THE REACTION SPEED OF THE EAC VALVE IS FAST ENOUGH THAT IT MIGHT MAKE A "POPPING" SOUND AS IT REACTS TO A LARGE IDLE LOAD. THIS IS A NORMAL CHARACTERISTIC AND NO ATTEMPTS SHOULD BE MADE IN AN EFFORT TO MODIFY THE PERFORMANCE OF THE IAC VALVE. IF POSSIBLE, COMPARE AGAINST A LIKE VEHICLE. 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. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Cap: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4827 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4828 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4829 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4830 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4831 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Cap: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4837 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4838 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4839 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4840 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4841 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Page 4842 Fuel Filler Cap: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Page 4843 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Page 4844 Fuel Filler Cap: Description and Operation FUEL FILLER CAP Fuel Filler Cap The fuel filler cap (Figure 100) is used to prevent fuel spill and close the evaporative emission/fuel system to atmosphere. Some vehicles may have a Fuel Cap Off Indicator Lamp (FCIL) in the instrument cluster which will illuminate when there is a failure in the vapor management system that may be due to the fuel filler cap not being sealed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR 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. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 4849 Fuel Pressure Release: Service and Repair Fuel Pressure Gauge SPECIAL SERVICE TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR 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. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and attach the Fuel Pressure Gauge. 2. Open the manual valve on the Fuel Pressure Gauge slowly and relieve the fuel pressure. NOTE: Open the manual valve slowly to relieve the system pressure. This may drain fuel from the system. Place the fuel in a suitable container. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 4850 Fuel Pressure Gauge Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair Fuel Injector Wiring Harness: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the upper and lower intake manifolds. For additional information, refer to Engine. 3. Disconnect the three (LH) fuel injector electrical connectors. NOTE: One connector is shown, the other two are similar. 4. Disconnect the (RH) fuel injector electrical connector. 5. Disconnect the engine bulkhead electrical connector. 6. Disconnect the Powertrain Control Module (PCM) electrical connector. 7. Disconnect the Heated Oxygen Sensor (HO2S) connectors. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Page 4855 8. Disconnect the electrical connectors. ^ ignition coil ^ radio ignition interference capacitor 9. Disconnect the electrical connectors. ^ Engine Coolant Temperature (ECT) sensor ^ water temperature indicator sender unit 10. Disconnect the backpressure transducer electrical connector. 11. Disconnect the Camshaft Position (CMP) sensor electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service and Repair > Page 4856 12. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 13. Remove the wiring harness from the vehicle. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions Fuel Line Coupler: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR 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. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. ^ THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings Fuel Line Coupler: Service and Repair Push Connect Fittings Fuel Line Removal Tool SPECIAL SERVICE TOOL(S) DISCONNECT WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR 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. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Relieve the fuel pressure. For additional information, refer to Fuel Pressure Release. See: Fuel Filter/Fuel Pressure Release 2. Disconnect the safety clip from the male hose. 3. Install the Fuel Line Disconnect Tool and push it into the fitting. 4. Separate the fittings. ^ Inspect for damage. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 4862 ^ Clean the fittings. CONNECT 1. Align the tube to the fitting and push until you hear a click. NOTE: Lubricate the tube end with clean engine oil meeting Ford specification WSS-M2C153-G to ease assembly. 2. Pull on the fitting to make sure it is fully engaged, then install the safety clip. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 4863 Fuel Line Coupler: Service and Repair R-Clip Fittings DISCONNECT WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR 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. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. CAUTION: Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. 1. Relieve the fuel pressure. For additional information, refer to Fuel Pressure Release. See: Fuel Filter/Fuel Pressure Release 2. Remove the shipping tab by bending downward. 3. Spread the R-clip legs and push the clip into the fitting. 4. Separate the fitting from the tube. CONNECT 1. Inspect the fitting and the tube for damage. Remove any dirt or obstructions. 2. Apply a light coat of clean engine oil meeting Ford specification WSS-M2C153-G to the male tube end. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 4864 3. Insert the R-clip into the fitting. 4. Align the tube and the fitting. 5. Insert the tube into the fitting and push together until a click is heard. 6. Pull on the connection to make sure it is fully engaged. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 4865 Fuel Line Coupler: Service and Repair Spring Lock Couplings SPECIAL SERVICE TOOL(S) DISCONNECT WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR 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. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Relieve the fuel pressure. For additional information, refer to Fuel Pressure Release. See: Fuel Filter/Fuel Pressure Release 2. Remove the fuel tube clip. 3. Install the Spring Lock Coupler Tool. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 4866 4. Close and push the Spring Lock Coupler Tool into the open side of the cage. 5. Separate the fitting. 6. Remove the Spring Lock Coupler Tool. CONNECT 1. Connect the fitting. ^ Inspect and clean both the coupling ends. ^ Lubricate the O-rings with clean engine oil meeting Ford specification WSS-M2C153-G. ^ Connect the fitting. ^ Pull on the fitting to make sure it is fully engaged. ^ Install the safety clip. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Push Connect Fittings > Page 4867 Fuel Line Coupler: Service and Repair Vapor Tube Fittings DISCONNECT 1. Disconnect the battery ground cable. For additional information, refer to Battery. WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. 2. Disconnect the vapor tube from the fitting. 1 Squeeze the fitting. 2 Disconnect the vapor tube from the fitting. CONNECT 1. Inspect the fitting and the tube for damage. 2. Remove any dirt or obstructions. 3. Push the tube into the fitting until it snaps in place. 4. Pull on the connection to make sure the fitting is secure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 4868 Fuel Line Coupler: Tools and Equipment Fuel Line Disconnect Tool Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations Fuel Pressure Regulator: Locations FUEL PUMP MODULE Fuel Pump Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 4872 Fuel Pump Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 4873 Mechanical Returnless Fuel Pump Module (FPM) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 4874 Electronic Returnless Fuel Pump Module (FPM) The Fuel Pump (FP) module (Figure 66), (Figure 67) and (Figure 68) is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 4875 Fuel Pressure Regulator: Description and Operation FUEL PUMP MODULE Fuel Pump Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 4876 Fuel Pump Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 4877 Mechanical Returnless Fuel Pump Module (FPM) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 4878 Electronic Returnless Fuel Pump Module (FPM) The Fuel Pump (FP) module (Figure 66), (Figure 67) and (Figure 68) is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation Fuel Pressure Sensor/Switch: Description and Operation FUEL RAIL PRESSURE SENSOR Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor (Figure 31) is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor (Figure 32) senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Fuel Pressure Relief Valve Bolts 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information Fuel Pressure Test Port: Technician Safety Information WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information > Page 4887 Fuel Pressure Test Port: Vehicle Damage Warnings CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Service Precautions > Page 4888 Fuel Pressure Test Port: Description and Operation PRESSURE TEST POINT There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE TEST KIT #134-ROO87 OR EQUIVALENT. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Service Precautions > Page 4889 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Remove the upper intake manifold. For additional information, refer to Engine. 2. Disconnect fuel supply line. 3. Remove the four bolts and the fuel supply line from the fuel supply manifold. 4. Remove the fuel supply line bracket bolt and the fuel supply line. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. NOTE: Lubricate the new O-ring seals with Super Premium SAE 5W-30 Motor Oil, XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G, to aid installation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Service Precautions > Technician Safety Information Fuel Pressure Pulsation Damper: Technician Safety Information WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL- RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Service Precautions > Technician Safety Information > Page 4894 Fuel Pressure Pulsation Damper: Vehicle Damage Warnings CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Service Precautions > Page 4895 Fuel Pressure Pulsation Damper: Description and Operation FUEL RAIL PULSE DAMPER Pulse Damper The fuel rail pulse damper (Figure 71) located on the fuel rail reduces fuel system noise caused by the pulsing of the fuel injectors. The vacuum port located on the damper is connected to manifold vacuum to avoid fuel spillage in the event the pulse damper diaphragm were to rupture. (The pulse damper should not be confused with a fuel pressure regulator, it does not regulate fuel rail pressure.) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Service Precautions > Page 4896 Fuel Pressure Pulsation Damper: Service and Repair REMOVAL WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL- RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Remove the fuel injection supply manifold. For additional information, refer to Fuel Rail. 2. Remove the two bolts, the fuel pulse damper and the O-ring seals. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. NOTE: Lubricate the new O-ring seals with Super Premium SAE 5W-30 Motor Oil, XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G, to aid installation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Fuel Pressure Relief Valve Bolts 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information Fuel Pressure Test Port: Technician Safety Information WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information > Page 4904 Fuel Pressure Test Port: Vehicle Damage Warnings CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 4905 Fuel Pressure Test Port: Description and Operation PRESSURE TEST POINT There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE TEST KIT #134-ROO87 OR EQUIVALENT. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 4906 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Remove the upper intake manifold. For additional information, refer to Engine. 2. Disconnect fuel supply line. 3. Remove the four bolts and the fuel supply line from the fuel supply manifold. 4. Remove the fuel supply line bracket bolt and the fuel supply line. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals. NOTE: Lubricate the new O-ring seals with Super Premium SAE 5W-30 Motor Oil, XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G, to aid installation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 4910 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 4911 Fuel Pump Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Specifications Fuel Rail: Specifications Fuel Injection Supply Manifold Bolts 25 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Technician Safety Information Fuel Rail: Technician Safety Information WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Technician Safety Information > Page 4917 Fuel Rail: Vehicle Damage Warnings CAUTION: This vehicle is equipped with a composite material fuel supply manifold. If the supply manifold is used as a leverage device, damage may occur to the supply manifold. Care must be taken when working around the supply manifold. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Page 4918 Fuel Rail: Description and Operation The fuel injection supply manifold: ^ delivers fuel to the individual fuel injectors. ^ receives fuel from the fuel supply line. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Page 4919 Fuel Rail: Service and Repair REMOVAL WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: This vehicle is equipped with a composite material fuel supply manifold. If the supply manifold is used as a leverage device, damage may occur to the supply manifold. Care must be taken when working around the supply manifold. 1. Remove the upper intake manifold. For additional information, refer to Engine. 2. Disconnect the fuel line. NOTE: After disconnecting the fuel line, plug the line to prevent leaks. 3. Disconnect the three LH fuel injector electrical connectors. NOTE: One connector is shown, the other two are similar. 4. Disconnect the RH fuel injector electrical connector. 5. Remove the four bolts from the fuel supply line. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service Precautions > Page 4920 6. Disconnect the fuel pulse damper vacuum hose. 7. Remove the fuel injection supply manifold. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Specifications Fuel Supply Line: Specifications Fuel Supply Line Support Bracket bolt 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Specifications > Page 4924 Fuel Supply Line: Tools and Equipment 3/8" Fuel Line Remover AST tool# 8013 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Specifications > Page 4925 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Specifications > Page 4926 8107 - 7-Piece Line Disconnect Set Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Hose: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4936 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4937 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4938 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4939 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4940 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Hose: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4946 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4947 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4948 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4949 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4950 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 4951 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 4952 Fuel Filler Hose: Description and Operation The fuel filler pipe check valve is an integral part of the fuel tank or the fuel filler pipe. It is intended to prevent liquid fuel from re-entering the fuel filler pipe from the fuel tank on refueling or rollover conditions. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 4953 Fuel Filler Hose: Service and Repair REMOVAL 1. Remove the fuel tank filler cap. 2. Remove the screws. 3. Remove the fuel tank filler pipe and the vent hose from the fuel tank and remove the fuel tank filler pipe. INSTALLATION 1. Install the fuel tank filler pipe and the vent hose. 1 Orient clamp bonding patch with top of the fuel tank. 2 Tighten the hose clamps. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 4954 2. Install the three fuel tank filler pipe screws. 3. Install the fuel tank filler cap. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Neck: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4963 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4964 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4965 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4966 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4967 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Neck: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4973 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4974 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4975 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4976 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4977 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Testing and Inspection Fuel Gauge Sender: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Testing and Inspection > Page 4981 Fuel Gauge Sender: Service and Repair Service and Repair For further information regarding this component please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications Idle Air Control Valve: Specifications Idle Air Control Valve Bolts 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 4988 Idle Air Control Valve: Description and Operation IDLE AIR CONTROL VALVE Nippondenso Idle Air Control (IAC) Valve Assembly Hitachi Idle Air Control (IAC) Valve Assembly With Vent/Filter The Idle Air Control (IAC) valve assembly (Figure 117) and (Figure 118) controls engine idle speed and provides a dashpot function. The IAC valve assembly meters intake air around the throttle plate through a bypass within the IAC valve assembly and throttle body. The PCM determines the desired idle speed or bypass air and signals the IAC valve assembly through a specified duty cycle. The IAC valve responds by positioning the IAC valve to control the amount of bypassed air. The PCM monitors engine rpm and increases or decreases the IAC duty cycle in order to achieve the desired rpm. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 4989 Hitachi Idle Air Control (IAC) Valve Assembly With Air-Assist Injectors On applications with air-assisted injectors, the IAC valve (Figure 119) also supplies a small amount of air into the path of the fuel injectors. The jet of air causes an increase in fuel atomization at low speed and light load conditions. NOTE: The IAC Valve Assembly is NOT ADJUSTABLE and CANNOT BE CLEANED. The IAC valve (part of throttle body assembly) has an internal diode on some applications. If the internal diode is measured in crossed terminal position with a digital multimeter, there will be an incorrect or negative reading. It is important that the mating component and harness connectors correctly oriented. Diagnostic procedures emphasize this importance. The PCM uses the IAC valve assembly to control: ^ No touch start ^ Cold engine fast idle for rapid warm-up ^ Idle (corrects for engine load) ^ Stumble or stalling on deceleration (provides a dashpot function) ^ Over-temperature idle boost. ^ Air Assist to Injectors. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 4990 Idle Air Control Valve: Testing and Inspection 1. Open the hood. 2. Verify the condition by operating the vehicle for a short time. NOTE: ^ Key symptom is elevated idle speed while noise is occurring. ^ "Snapping" the throttle can induce the noise. 3. Inspect the IAC valve. If physical evidence of contamination exists, install a new IAC valve. 4. While the noise is occurring, either place an Engine EAR probe near the IAC valve and the inlet tube, or create a 6.35 mm (0.25 in) - 12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the IAC valve is making the noise, install a new IAC valve. 5. Test the vehicle for normal operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 4991 Idle Air Control Valve: Service and Repair REMOVAL NOTE: The 5.0L is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the accelerator control snow shield. 3. Disconnect the idle air control (IAC) valve electrical connector. 4. Remove the IAC valve and discard the gasket. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Install a new IAC valve gasket. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 4995 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch (Figure 72) is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner Guide for the location of the IFS. Inertia Fuel Shutoff (IFS) Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 4996 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Disconnect the battery. For additional information, refer to Battery. 2. Access the Inertia Fuel Shutoff (IFS) switch on the RH toe board and disconnect the electrical connector. 3. Remove the bolts and remove the IFS switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair Intake Air Duct: Service and Repair REMOVAL 1. Remove the engine appearance cover. ^ Disconnect the speed control cable (if equipped). ^ Remove the bolts. 2. Remove the air cleaner outlet tube. 1 Unclip the wire harness 2 Disconnect the crankcase ventilation tubes. 3 Loosen the air cleaner outlet tube clamps and remove the air cleaner outlet tube. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Make sure the screw clamps do not interfere with the throttle body cam. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 5003 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 5004 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 5009 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 5010 Fuel Pump Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 5014 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 5015 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications Mass Air Flow Sensor: Specifications Mass Air Flow Sensor Nuts And Bolts 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 5020 Mass Air Flow Sensor: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 5021 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 5022 Mass Air Flow Sensor: Description and Operation MASS AIR FLOW SENSOR Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure Control (EPC), shift and torque converter clutch scheduling. Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar, Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 5023 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 3. Loosen the air cleaner outlet tube clamp and position aside. 4. Remove the four bolts and the MAF sensor. CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the MAF body. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation Fuel Pressure Sensor/Switch: Description and Operation FUEL RAIL PRESSURE SENSOR Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor (Figure 31) is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor (Figure 32) senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 5030 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch (Figure 72) is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner Guide for the location of the IFS. Inertia Fuel Shutoff (IFS) Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 5031 Inertia Fuel Shutoff Switch: Service and Repair REMOVAL 1. Disconnect the battery. For additional information, refer to Battery. 2. Access the Inertia Fuel Shutoff (IFS) switch on the RH toe board and disconnect the electrical connector. 3. Remove the bolts and remove the IFS switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 5035 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs Throttle Position Sensor: Description and Operation PCM Inputs THROTTLE POSITION SENSOR Typical Throttle Position (TP) Sensor The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs > Page 5038 Throttle Position Sensor: Description and Operation Intake Air Systems THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the On-Board Diagnostic (OBD) II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 5039 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the accelerator control snow shield. 3. Remove the Throttle Position (TP) sensor. 1 Disconnect the TP sensor electrical connector. 2 Remove the sensor. NOTE: The 4.0L (SOHC) is shown, the 4.0L push rod is similar. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications Throttle Body: Specifications Throttle Body Bolts 7 Nm Throttle Body-to-upper Intake Manifold Bolts 8 - 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Technician Safety Information Throttle Body: Technician Safety Information WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service Precautions > Technician Safety Information > Page 5045 Throttle Body: Vehicle Damage Warnings CAUTION: Throttle body bore and plate area have a special coating and cannot be cleaned, or possible damage to the throttle body may occur. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Description and Operation > Throttle Body Housing Throttle Body: Description and Operation Throttle Body Housing THROTTLE BODY HOUSING The throttle body housing assembly is a single piece of aluminum casting with an air passage and a butterfly throttle plate with linkage mechanisms. When the throttle plate is in the idle (or closed) position, the throttle lever arm should be in contact with the Throttle Return Stop. The throttle return stop prevents the throttle plate from contacting the bore and sticking closed. The setting also establishes the amount of air flow between the throttle plate and bore. To minimize the closed plate air flow, a special coating is applied to the throttle plate and bore to help seal this area. This sealant/coating also makes the throttle body resistant to engine intake sludge accumulation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Description and Operation > Throttle Body Housing > Page 5048 Throttle Body: Description and Operation Throttle Body System Overview THROTTLE BODY SYSTEM OVERVIEW The throttle body system meters air to the engine during idle, part throttle, and Wide Open Throttle (WOT) conditions. The throttle body system consists of an Idle Air Control (IAC) valve assembly, idle air orifice, single or dual bores with butterfly valve throttle plates and a Throttle Position (TP) sensor. One other source of idle air flow is the Positive Crankcase Ventilation (PCV) system. The combined idle air flow (from idle air orifice IAC flow and PCV flow) is measured by the MAF sensor on all applications. During idle, the throttle body assembly provides a set amount of air flow to the engine through the idle air passage and PCV valve. The IAC valve assembly provides additional air when commanded by the Powertrain Control Module (PCM) to maintain the proper engine idle speed under varying conditions. The IAC valve assembly mounts directly to the throttle body assembly in most applications, but is remote-mounted to the intake manifold in some applications. Idle speed is controlled by the PCM and cannot be adjusted. NOTE: The traditional idle air adjust procedure as well as throttle return screw are no longer used on OBD II applications. Throttle rotation is controlled by a cam/cable linkage to slow the initial opening rate of the throttle plate. The TP sensor monitors throttle position and provides an electrical signal to the PCM. Some throttle body applications provide an air supply channel upstream of the throttle plate to provide fresh air to the Positive Crankcase Ventilation (PCV) or IAC systems. Other throttle body applications provide individual vacuum taps downstream of the throttle plate for PCV return, Exhaust Gas Recirculation (EGR), Evaporative Emission (EVAP), and miscellaneous control signals. Throttle Body System Hardware The major components of the throttle body assembly include the TP sensor, IAC valve assembly, and throttle body housing assembly. Throttle Position Sensor The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the On-Board Diagnostic (OBD) II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Idle Air Control Valve Nippondenso Idle Air Control (IAC) Valve Assembly Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Description and Operation > Throttle Body Housing > Page 5049 Hitachi Idle Air Control (IAC) Valve Assembly With Vent/Filter The Idle Air Control (IAC) valve assembly (Figure 117) and (Figure 118) controls engine idle speed and provides a dashpot function. The IAC valve assembly meters intake air around the throttle plate through a bypass within the IAC valve assembly and throttle body. The PCM determines the desired idle speed or bypass air and signals the IAC valve assembly through a specified duty cycle. The IAC valve responds by positioning the IAC valve to control the amount of bypassed air. The PCM monitors engine rpm and increases or decreases the IAC duty cycle in order to achieve the desired rpm. Hitachi Idle Air Control (IAC) Valve Assembly With Air-Assist Injectors On applications with air-assisted injectors, the IAC valve (Figure 119) also supplies a small amount of air into the path of the fuel injectors. The jet of air causes an increase in fuel atomization at low speed and light load conditions. NOTE: The IAC Valve Assembly is NOT ADJUSTABLE and CANNOT BE CLEANED. The IAC valve (part of throttle body assembly) has an internal diode on some applications. If the internal diode is measured in crossed terminal position with a digital multimeter, there will be an incorrect or negative reading. It is important that the mating component and harness connectors correctly oriented. Diagnostic procedures emphasize this importance. The PCM uses the IAC valve assembly to control: ^ No touch start Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Description and Operation > Throttle Body Housing > Page 5050 ^ Cold engine fast idle for rapid warm-up ^ Idle (corrects for engine load) ^ Stumble or stalling on deceleration (provides a dashpot function) ^ Over-temperature idle boost. ^ Air Assist to Injectors. Throttle Body Housing The throttle body housing assembly is a single piece of aluminum casting with an air passage and a butterfly throttle plate with linkage mechanisms. When the throttle plate is in the idle (or closed) position, the throttle lever arm should be in contact with the Throttle Return Stop. The throttle return stop prevents the throttle plate from contacting the bore and sticking closed. The setting also establishes the amount of air flow between the throttle plate and bore. To minimize the closed plate air flow, a special coating is applied to the throttle plate and bore to help seal this area. This sealant/coating also makes the throttle body resistant to engine intake sludge accumulation. Typical Attention Decal Locations Features of the Throttle Body Assembly include: 1. Idle Air Control (IAC) valve assembly mounted directly to the throttle body assembly (some vehicles). 2. A pre-set stop to locate the WOT position. 3. An air supply channel upstream of the throttle plate to provide fresh air to the PCV system (some vehicles only). 4. Individual vacuum taps for PCV, EGR, Evaporative Emission (EVAP) and miscellaneous control signals (some vehicles only). 5. PCV air return (it applicable). 6. A throttle body-mounted Throttle Position (TP) sensor. 7. A sealant/coating on the throttle bore and throttle plate makes the throttle body air flow tolerant to engine intake sludge accumulation. These throttle body assemblies MUST NOT BE CLEANED and have a white/black attention decal (Figure 116) advising not to clean. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Description and Operation > Page 5051 Throttle Body: Service and Repair REMOVAL WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: Throttle body bore and plate area have a special coating and cannot be cleaned, or possible damage to the throttle body may occur. 1. Remove the air cleaner outlet tube. 2. Disconnect the Throttle Position (TP) sensor electrical connector. 3. Disconnect the accelerator cable and the speed control cable (if equipped). 4. Remove the throttle body. NOTE: Discard the throttle body gasket. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications Throttle Cable/Linkage: Specifications Accelerator Cable Bracket To Coil Bracket Nut 8 - 10 Nm Accelerator Cable Bracket Stud Bolt 16 - 24 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications > Page 5055 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications > Page 5056 Throttle Cable/Linkage: Description and Operation The accelerator cable is controlled by an accelerator pedal and shaft. The pedal and shaft should travel smoothly from the idle to wide-open throttle positions. Failure to return or hesitation on return to the idle position must not occur. Surrounding components such as wiring, hoses, sound insulator and floor covering must not contact the sliding inner member of the accelerator cable or the accelerator pedal and shaft. The speed control speedometer cable and the accelerator cable are attached at the throttle lever on the throttle body. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Throttle Cable/Linkage: Initial Inspection and Diagnostic Overview NOTE: Care should be exercised when performing service on or around the accelerator pedal linkage and controls. 1. Inspect the accelerator pedal and shaft and attaching linkage for damage or distortion which would bind or limit accelerator travel. 2. Inspect the accelerator cable for kinks or fraying which may cause bending. 3. Inspect the engine idle speed adjustment to make sure of the correct idle speed specification after any accelerator linkage adjustment or repair. 4. Inspect throttle body for excessive wear or damage. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5059 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Testing and Inspection > Page 5060 Throttle Cable/Linkage: Service and Repair REMOVAL 1. Remove the screws and the accelerator control splash shield. 2. Disconnect the accelerator cable from the throttle body. 3. Disconnect the accelerator cable from the intake manifold. 1 Remove the screw. 2 Disconnect the accelerator cable from the intake manifold. 4. From inside the vehicle, disconnect the accelerator cable from the accelerator pedal and shaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Testing and Inspection > Page 5061 5. Collapse the clips at the dash panel and push the accelerator cable through the dash panel into the engine compartment and remove the accelerator cable. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 5065 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs Throttle Position Sensor: Description and Operation PCM Inputs THROTTLE POSITION SENSOR Typical Throttle Position (TP) Sensor The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing has a three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs > Page 5068 Throttle Position Sensor: Description and Operation Intake Air Systems THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the On-Board Diagnostic (OBD) II system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 5069 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the accelerator control snow shield. 3. Remove the Throttle Position (TP) sensor. 1 Disconnect the TP sensor electrical connector. 2 Remove the sensor. NOTE: The 4.0L (SOHC) is shown, the 4.0L push rod is similar. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Description and Operation Variable Induction Control Valve: Description and Operation INTAKE MANIFOLD TUNING VALVE (IMTV) Intake Manifold Tuning Valve (IMTV) 3.0L LS6 Intake Air System Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Description and Operation > Page 5074 4.6L E/F-Series Intake Air System Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Description and Operation > Page 5075 5.4L (4) Intake Air System The Intake Manifold Tuning Valve (IMTV) (Figure 107) is a motorized actuated unit mounted directly to the intake manifold. The IMTV actuator controls a shutter device attached to the actuator shaft. There is no monitor input to the PCM with this system to indicate shutter position. The motorized IMTV unit will not be energized below approximately 2600 rpm or higher on some vehicles. The shutter will be in the closed position not allowing airflow blend to occur in the intake manifold. Above approximately 2600 rpm or higher, the motorized unit will be energized. The motorized unit will be commanded on by the PCM initially at a 100 percent duty cycle to move the shutter to the open position and then falling to approximately 50 percent to continue to hold the shutter open. 1. The PCM uses the TP sensor and CKP signals to determine activation of the IMTV system. There must be a positive change in voltage from the TP sensor along with the increase in rpm to open the shutter. 2. The PCM uses the information from the input signals to control the IMTV. 3. When commanded on by the PCM, the motorized actuator shutter opens up the end of the vertical separating wall at high engine speeds to allow both sides of the manifold to blend together. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications Coil Terminal-To-Cylinder Relationship Firing order........................................................................................................................................... ..................................................................1-4-2-5-3-6 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Page 5080 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor, Stud Bolt 19 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 5088 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 5089 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 5090 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the CMP sensor electrical connector. 2 Remove the CMP sensor stud bolt. 3 Remove the camshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolts 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 5094 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Electronic Engine Controls Crankshaft Position Sensor: Description and Operation Electronic Engine Controls The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Electronic Engine Controls > Page 5097 Crankshaft Position Sensor: Description and Operation Standard Models (Non BI-Fuel) CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference (Figure 25). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Page 5098 Crankshaft Position Sensor: Service and Repair REMOVAL NOTE: The 5.0L is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Crankshaft Position (CKP) sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ 4.0L SOHC and 4.0L (push rod) CKP sensors need to be touching the damper. The CKP sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure sensor wiring is routed away from the battery cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service Precautions Ignition Cable: Service Precautions CAUTION: ^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. ^ Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service Precautions > Page 5102 Ignition Cable: Service and Repair Spark Plug Wire Remover SPECIAL SERVICE TOOL(S) REMOVAL CAUTION: ^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. 1. With a twisting motion, use the special tool to pull the spark plug wire off the spark plug. 2. Squeeze the locking tabs and twist while pulling upward to remove the spark plug wires from the ignition coil. 3. Remove the spark plug wires. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service Precautions > Page 5103 1. To install, reverse the removal procedure. CAUTION: Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold. NOTE: Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to the inside of the spark plug and ignition coil boots of the spark plug wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Mechanical Specifications Ignition Coil: Mechanical Specifications Ignition Coil Bolts 6 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 5108 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 5109 Ignition Coil: Service Precautions CAUTION: ^ Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 5110 Ignition Coil: Description and Operation Coil Pack Horizontal Connector Six Tower Coil Pack Series 5 Six Tower Coil Pack Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 5111 Four - Tower Coil Packs Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 5112 Series 5 Four Tower Coil Pack Coil packs come in four tower, Series 5 four tower, six-tower horizontal connector and Series 5 Six tower models. Two adjacent coil towers share a common coil and are called a matched pair. For six-tower coil pack (six cylinder) applications the matched pairs are 1 and 5, 2 and 6, and 3 and 4 (Figure 56)and (Figure 57). For four-tower coil pack (four cylinder) applications the matched pairs are 1 and 4, and 2 and 3 (Figure 58) and (Figure 59). When the coil is fired by the PCM, spark is delivered through the matched pair towers to their respective spark plugs. The spark plugs are fired simultaneously and are paired so that as one fires on the compression stroke, the other spark plug fires on the exhaust stroke. The next time the coil is fired the situation is reversed. The next pair of spark plugs fire according to the engine firing order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 5113 Ignition Coil: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the ignition coil electrical connections. 1 Squeeze the locking tabs and twist while pulling upward to disconnect the six spark plug wires. CAUTION: ^ Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire locations before removing them. ^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire. 2 Disconnect the ignition coil electrical connector. 3. Remove the ignition coil. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to the inside of the spark plug wire coil boots. ^ Be sure to reinstall the radio ignition interference capacitor under the correct ignition coil mounting bolt. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Bolt 25 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications > Page 5117 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications > Page 5118 Knock Sensor: Description and Operation Knock Sensor Two Types Of Knock Sensor (KS) The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications > Page 5119 Knock Sensor: Service and Repair REMOVAL 1. Remove the lower in take manifold. For additional information, refer to Engine. 2. Remove the knock sensor. 1 Remove the bolt. 2 Remove the knock sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft Position Sensor, Stud Bolt 19 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 5124 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 5125 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctance Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22) and the two pin connector variable reluctance sensor (Figure 23). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 5126 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Camshaft Position (CMP) sensor. 1 Disconnect the CMP sensor electrical connector. 2 Remove the CMP sensor stud bolt. 3 Remove the camshaft position sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position Sensor Bolts 10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 5130 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Electronic Engine Controls Crankshaft Position Sensor: Description and Operation Electronic Engine Controls The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Electronic Engine Controls > Page 5133 Crankshaft Position Sensor: Description and Operation Standard Models (Non BI-Fuel) CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is also able to identify piston travel in order to synchronize the ignition system and provide a way of tracking the angular position of the crankshaft relative to fixed reference (Figure 25). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Page 5134 Crankshaft Position Sensor: Service and Repair REMOVAL NOTE: The 5.0L is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the Crankshaft Position (CKP) sensor. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ 4.0L SOHC and 4.0L (push rod) CKP sensors need to be touching the damper. The CKP sensor has wear tabs that will wear off after several engine revolutions. ^ Be sure sensor wiring is routed away from the battery cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. 2. Prove out the air bag system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 5140 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 5141 4. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. Installation WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 5142 WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Note: Use a new ignition switch lock cylinder. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. 2. Prove out the air bag system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock Sensor Bolt 25 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 5146 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 5147 Knock Sensor: Description and Operation Knock Sensor Two Types Of Knock Sensor (KS) The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 5148 Knock Sensor: Service and Repair REMOVAL 1. Remove the lower in take manifold. For additional information, refer to Engine. 2. Remove the knock sensor. 1 Remove the bolt. 2 Remove the knock sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark Plug Gap 1.3 - 1.4 mm RH Original Spark Plug AGRF22PG LH Original Spark Plug AGRF22P New Spark Plug (Either Side) AGSF22PP Spark Plugs 20 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 5153 Spark Plug: Specifications Spark Plug Gap 1.3 - 1.4 mm RH Original Spark Plug AGRF22PG LH Original Spark Plug AGRF22P New Spark Plug (Either Side) AGSF22PP Spark Plugs 20 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5154 Spark Plug: Application and ID RH Original Spark Plug Type .............................................................................................................. .............................................................. AGRF22PG LH Original Spark Plug Type ............................ .................................................................................................................................................... AGRF22P New Spark Plug Type (Either Side) ................................................................................... ................................................................................. AGSF22PP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5155 Spark Plug: Service and Repair REMOVAL 1. Remove the spark plug wires. For additional information, refer to Ignition Cable. 2. Remove the spark plugs. NOTE: ^ Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs. ^ If an original spark plug is reused, make sure it is installed in the same cylinder it was taken from. New spark plugs can be used in any cylinder. 3. Inspect the spark plugs. 4. Use a suitable spark plug gap tool to check and adjust the spark plug gap. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Pressure Regulating Solenoid: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5162 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5163 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5164 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Pressure Regulating Solenoid: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5167 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5168 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5169 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5170 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5171 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5172 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5173 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5174 Pressure Regulating Solenoid: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5175 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5176 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5177 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5178 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5179 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5180 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5181 Diagram 29-4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5182 Pressure Regulating Solenoid: Description and Operation Electronic Pressure Control (EPC) Solenoid The electronic pressure control (EPC) solenoid is a variable force style (VFS) solenoid. The VFS type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve. The powertrain control module varies the current to the EPC solenoid. This action causes the solenoid to regulate transmission line pressure and line modulator pressure. This is done by producing resisting forces to the main regulator and line modulator circuits. These two solenoids control clutch application pressures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5183 Pressure Regulating Solenoid: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. Loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 7. Note: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5184 8. Disconnect the appropriate solenoid electrical connector. 1. Disconnect shift solenoids electrical connectors. 2. Disconnect the torque converter clutch (TCC) solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid electrical connector. 9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. CAUTION: Shift solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the appropriate solenoid(s). Installation 1. Install the new solenoid(s). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5185 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the torque converter clutch (TCC) solenoid electrical connector. 3. Connect the electrical pressure control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1. Install the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5186 2. Install the transmission fluid filter screw. 6. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. - Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. Connect the battery ground cable. 11. Fill the transmission to the proper fluid level and check for proper transmission operation. - Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications Shift Lock Actuator Bolts 62.5-98 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5190 Shift Interlock Solenoid: Service and Repair Removal 1. Remove the steering column assembly. 2. Remove the insert plate and shift lock actuator. 1. Remove the bolts. 2. Remove the insert plate and shift lock actuator. 3. Note: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced. Remove the insert plate from the shift lock actuator. Remove and discard the shift lock actuator clip. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Shift Solenoid: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 5194 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 5195 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 5196 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5199 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5200 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5201 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5202 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5203 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5204 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5205 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5206 Shift Solenoid: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5207 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5208 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5209 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5210 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5211 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5212 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5213 Diagram 29-4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5214 Shift Solenoid: Description and Operation Shift Solenoids A, B, C, and D Four On/Off shift solenoids allow the powertrain control module to control shift scheduling. - The solenoids are two-way, normally open style. - The shift solenoids (SSA, SSB, SSC, and SSD) provide gear selection by controlling the pressures of the shift valves. - SSD is also used to apply and release the coast clutch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5215 Shift Solenoid: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. Loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 7. Note: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5216 8. Disconnect the appropriate solenoid electrical connector. 1. Disconnect shift solenoids electrical connectors. 2. Disconnect the torque converter clutch (TCC) solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid electrical connector. 9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. CAUTION: Shift solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the appropriate solenoid(s). Installation 1. Install the new solenoid(s). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5217 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the torque converter clutch (TCC) solenoid electrical connector. 3. Connect the electrical pressure control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1. Install the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5218 2. Install the transmission fluid filter screw. 6. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. - Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. Connect the battery ground cable. 11. Fill the transmission to the proper fluid level and check for proper transmission operation. - Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Bolt 80-97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5222 Torque Converter Clutch Solenoid: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5223 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5224 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5225 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5228 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5229 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5230 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5231 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5232 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5233 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5234 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5235 Torque Converter Clutch Solenoid: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5236 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5237 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5238 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5239 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5240 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5241 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5242 Diagram 29-4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5243 Torque Converter Clutch Solenoid: Description and Operation Torque Converter Clutch (TCC) Solenoid The torque converter clutch (TCC) solenoid is used to control the apply and release of the TCC. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5244 Torque Converter Clutch Solenoid: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. Loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 7. Note: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5245 8. Disconnect the appropriate solenoid electrical connector. 1. Disconnect shift solenoids electrical connectors. 2. Disconnect the torque converter clutch (TCC) solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid electrical connector. 9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. CAUTION: Shift solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the appropriate solenoid(s). Installation 1. Install the new solenoid(s). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5246 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the torque converter clutch (TCC) solenoid electrical connector. 3. Connect the electrical pressure control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1. Install the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5247 2. Install the transmission fluid filter screw. 6. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. - Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. Connect the battery ground cable. 11. Fill the transmission to the proper fluid level and check for proper transmission operation. - Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations > Page 5253 Overdrive Indicator Lamp: Description and Operation Overdrive (O/D) Off The O/D OFF indicator illuminates when the transmission is locked out of O/D. This dual function indicator will also flash off and on if a transmission malfunction is detected. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Locations > Page 5257 Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the gearshift lever in the (D) position. - Rotate the gearshift lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (D) position). 3. Hang a 3.6 kg (8 lb.) weight on the gearshift lever. 4. Center the pointer in the middle of the (D) position. - Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer. 5. Remove the 3.6 kg (8 lb.) weight. 6. Carefully move the gearshift lever from detent to detent and compare with the transmission settings. - Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation TRANSMISSION CONTROL INDICATOR LAMP The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to Transmission Control Switch, PCM Inputs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Service and Repair Control Module: Service and Repair Removal 1. Remove the transmission control switch (TCS). 1. Remove the TCS cover. 2. Remove the TCS. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital transmission range (TR) sensor screws 71 - 97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5278 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5279 Digital Transmission Range Sensor: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5280 Digital Transmission Range Sensor: Service and Repair Special Tools Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the shift cable. 1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the bracket. 4. Disconnect the digital transmission range (TR) sensor electrical connector. 5. Remove the manual control outer lever nut and manual control outer lever. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5281 6. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor. 1. Position the digital TR sensor. 2. Loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Note: The manual lever must he in the neutral position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever. 1. Install the manual control outer lever. 2. Install the manual control outer lever nut. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5282 4. Connect the digital transmission range (TR) sensor electrical connector. 5. Connect the shift cable. 1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. Connect the battery ground cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Specifications Transmission Speed Sensor: Specifications Turbine shaft speed (TSS) sensor screw 71 - 97 in.lb Output shaft speed sensor (OSS) sensor screw 71 - 97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Specifications > Page 5286 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions Transmission Speed 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 SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 5289 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 5290 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 5291 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 5292 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 5293 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 5294 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 5295 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 5296 Transmission Speed Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 5297 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 5298 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 5299 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 5300 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 5301 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 5302 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 5303 Transmission Speed Sensor: Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 5304 Diagram 29-4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Page 5305 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Service and Repair > Transfer Case - Automatic Shift Transmission Speed Sensor: Service and Repair Transfer Case - Automatic Shift Output Shaft Speed Sensor-Front Removal 1. Remove the transfer case shift motor. 2. Remove the front output shaft speed sensor. 1. Remove the bolt. 2. Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Output Shaft Speed Sensor-Rear Removal Warning: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. 1. Raise and support vehicles. 2. Disconnect the electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Service and Repair > Transfer Case - Automatic Shift > Page 5308 3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector. 1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover. 4. Remove the bolt and the sensor. Installation 1. Caution: Make sure the sensor seats flat against the boss To install, reverse the removal procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Service and Repair > Transfer Case - Automatic Shift > Page 5309 Transmission Speed Sensor: Service and Repair 5R55E Removal 1. Raise and support the vehicle. 2. Disconnect output shaft speed (OSS) sensor electrical connector. 3. Remove OSS sensor. 1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission. - Inspect the OSS sensor O-ring for damage. If damaged, replace the O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Service and Repair > Transfer Case - Automatic Shift > Page 5310 2. Connect OSS sensor electrical connector. 3. Lower the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations The Transmission Fluid Temperature Sensor is located on the main control body wiring harness assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5316 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5317 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5318 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5319 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5320 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5321 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5322 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5323 Transmission Temperature Sensor/Switch: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5324 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5325 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5326 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5327 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5328 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5329 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5330 Diagram 29-4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 5331 Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference voltage signal. The resistance in the TFT varies with temperature. The powertrain control module (PCM) monitors the voltage signal across the TFT, and uses this information to determine the transmission fluid temperature. The TFT is located on the main control body wiring harness assembly. The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation and electronic pressure control (EPC). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Specifications Transmission Speed Sensor: Specifications Turbine shaft speed (TSS) sensor screw 71 - 97 in.lb Output shaft speed sensor (OSS) sensor screw 71 - 97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Specifications > Page 5336 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > 4R70W Transmission Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > 4R70W Transmission > Page 5339 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Page 5340 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Service and Repair > Transfer Case - Automatic Shift Transmission Speed Sensor: Service and Repair Transfer Case - Automatic Shift Output Shaft Speed Sensor-Front Removal 1. Remove the transfer case shift motor. 2. Remove the front output shaft speed sensor. 1. Remove the bolt. 2. Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Output Shaft Speed Sensor-Rear Removal Warning: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. 1. Raise and support vehicles. 2. Disconnect the electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Service and Repair > Transfer Case - Automatic Shift > Page 5343 3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector. 1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover. 4. Remove the bolt and the sensor. Installation 1. Caution: Make sure the sensor seats flat against the boss To install, reverse the removal procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Service and Repair > Transfer Case - Automatic Shift > Page 5344 Transmission Speed Sensor: Service and Repair 5R55E Removal 1. Raise and support the vehicle. 2. Disconnect output shaft speed (OSS) sensor electrical connector. 3. Remove OSS sensor. 1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission. - Inspect the OSS sensor O-ring for damage. If damaged, replace the O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Service and Repair > Transfer Case - Automatic Shift > Page 5345 2. Connect OSS sensor electrical connector. 3. Lower the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures PROM - Programmable Read Only Memory: Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 5350 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 5351 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Pressure Regulating Solenoid: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5358 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5359 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5360 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Pressure Regulating Solenoid: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5363 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5364 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5365 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5366 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5367 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5368 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5369 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5370 Pressure Regulating Solenoid: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5371 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5372 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5373 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5374 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5375 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5376 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5377 Diagram 29-4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5378 Pressure Regulating Solenoid: Description and Operation Electronic Pressure Control (EPC) Solenoid The electronic pressure control (EPC) solenoid is a variable force style (VFS) solenoid. The VFS type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve. The powertrain control module varies the current to the EPC solenoid. This action causes the solenoid to regulate transmission line pressure and line modulator pressure. This is done by producing resisting forces to the main regulator and line modulator circuits. These two solenoids control clutch application pressures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5379 Pressure Regulating Solenoid: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. Loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 7. Note: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5380 8. Disconnect the appropriate solenoid electrical connector. 1. Disconnect shift solenoids electrical connectors. 2. Disconnect the torque converter clutch (TCC) solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid electrical connector. 9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. CAUTION: Shift solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the appropriate solenoid(s). Installation 1. Install the new solenoid(s). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5381 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the torque converter clutch (TCC) solenoid electrical connector. 3. Connect the electrical pressure control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1. Install the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5382 2. Install the transmission fluid filter screw. 6. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. - Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. Connect the battery ground cable. 11. Fill the transmission to the proper fluid level and check for proper transmission operation. - Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications Shift Lock Actuator Bolts 62.5-98 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5386 Shift Interlock Solenoid: Service and Repair Removal 1. Remove the steering column assembly. 2. Remove the insert plate and shift lock actuator. 1. Remove the bolts. 2. Remove the insert plate and shift lock actuator. 3. Note: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced. Remove the insert plate from the shift lock actuator. Remove and discard the shift lock actuator clip. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Shift Solenoid: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 5390 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 5391 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 5392 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5395 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5396 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5397 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5398 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5399 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5400 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5401 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5402 Shift Solenoid: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5403 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5404 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5405 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5406 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5407 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5408 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5409 Diagram 29-4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5410 Shift Solenoid: Description and Operation Shift Solenoids A, B, C, and D Four On/Off shift solenoids allow the powertrain control module to control shift scheduling. - The solenoids are two-way, normally open style. - The shift solenoids (SSA, SSB, SSC, and SSD) provide gear selection by controlling the pressures of the shift valves. - SSD is also used to apply and release the coast clutch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5411 Shift Solenoid: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. Loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 7. Note: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5412 8. Disconnect the appropriate solenoid electrical connector. 1. Disconnect shift solenoids electrical connectors. 2. Disconnect the torque converter clutch (TCC) solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid electrical connector. 9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. CAUTION: Shift solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the appropriate solenoid(s). Installation 1. Install the new solenoid(s). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5413 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the torque converter clutch (TCC) solenoid electrical connector. 3. Connect the electrical pressure control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1. Install the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5414 2. Install the transmission fluid filter screw. 6. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. - Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. Connect the battery ground cable. 11. Fill the transmission to the proper fluid level and check for proper transmission operation. - Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Bolt 80-97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5418 Torque Converter Clutch Solenoid: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5419 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5420 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5421 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5424 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5425 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5426 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5427 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5428 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5429 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5430 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5431 Torque Converter Clutch Solenoid: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5432 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5433 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5434 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5435 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5436 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5437 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5438 Diagram 29-4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5439 Torque Converter Clutch Solenoid: Description and Operation Torque Converter Clutch (TCC) Solenoid The torque converter clutch (TCC) solenoid is used to control the apply and release of the TCC. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5440 Torque Converter Clutch Solenoid: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. Loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 7. Note: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5441 8. Disconnect the appropriate solenoid electrical connector. 1. Disconnect shift solenoids electrical connectors. 2. Disconnect the torque converter clutch (TCC) solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid electrical connector. 9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. CAUTION: Shift solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the appropriate solenoid(s). Installation 1. Install the new solenoid(s). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5442 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the torque converter clutch (TCC) solenoid electrical connector. 3. Connect the electrical pressure control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1. Install the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5443 2. Install the transmission fluid filter screw. 6. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. - Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. Connect the battery ground cable. 11. Fill the transmission to the proper fluid level and check for proper transmission operation. - Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Pressure Regulating Solenoid: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5449 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5450 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5451 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Pressure Regulating Solenoid: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5454 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5455 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5456 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5457 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5458 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5459 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5460 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5461 Pressure Regulating Solenoid: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5462 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5463 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5464 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5465 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5466 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5467 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5468 Diagram 29-4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5469 Pressure Regulating Solenoid: Description and Operation Electronic Pressure Control (EPC) Solenoid The electronic pressure control (EPC) solenoid is a variable force style (VFS) solenoid. The VFS type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve. The powertrain control module varies the current to the EPC solenoid. This action causes the solenoid to regulate transmission line pressure and line modulator pressure. This is done by producing resisting forces to the main regulator and line modulator circuits. These two solenoids control clutch application pressures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5470 Pressure Regulating Solenoid: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. Loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 7. Note: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5471 8. Disconnect the appropriate solenoid electrical connector. 1. Disconnect shift solenoids electrical connectors. 2. Disconnect the torque converter clutch (TCC) solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid electrical connector. 9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. CAUTION: Shift solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the appropriate solenoid(s). Installation 1. Install the new solenoid(s). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5472 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the torque converter clutch (TCC) solenoid electrical connector. 3. Connect the electrical pressure control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1. Install the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5473 2. Install the transmission fluid filter screw. 6. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. - Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. Connect the battery ground cable. 11. Fill the transmission to the proper fluid level and check for proper transmission operation. - Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications Shift Lock Actuator Bolts 62.5-98 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5477 Shift Interlock Solenoid: Service and Repair Removal 1. Remove the steering column assembly. 2. Remove the insert plate and shift lock actuator. 1. Remove the bolts. 2. Remove the insert plate and shift lock actuator. 3. Note: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced. Remove the insert plate from the shift lock actuator. Remove and discard the shift lock actuator clip. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations Shift Solenoid: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Page 5481 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Page 5482 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Page 5483 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5486 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5487 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5488 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5489 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5490 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5491 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5492 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5493 Shift Solenoid: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5494 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5495 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5496 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5497 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5498 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5499 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5500 Diagram 29-4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5501 Shift Solenoid: Description and Operation Shift Solenoids A, B, C, and D Four On/Off shift solenoids allow the powertrain control module to control shift scheduling. - The solenoids are two-way, normally open style. - The shift solenoids (SSA, SSB, SSC, and SSD) provide gear selection by controlling the pressures of the shift valves. - SSD is also used to apply and release the coast clutch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5502 Shift Solenoid: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. Loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 7. Note: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5503 8. Disconnect the appropriate solenoid electrical connector. 1. Disconnect shift solenoids electrical connectors. 2. Disconnect the torque converter clutch (TCC) solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid electrical connector. 9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. CAUTION: Shift solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the appropriate solenoid(s). Installation 1. Install the new solenoid(s). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5504 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the torque converter clutch (TCC) solenoid electrical connector. 3. Connect the electrical pressure control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1. Install the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5505 2. Install the transmission fluid filter screw. 6. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. - Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. Connect the battery ground cable. 11. Fill the transmission to the proper fluid level and check for proper transmission operation. - Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Bolt 80-97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5509 Torque Converter Clutch Solenoid: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5510 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5511 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5512 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5515 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5516 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5517 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5518 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5519 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5520 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5521 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5522 Torque Converter Clutch Solenoid: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5523 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5524 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5525 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5526 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5527 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5528 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5529 Diagram 29-4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5530 Torque Converter Clutch Solenoid: Description and Operation Torque Converter Clutch (TCC) Solenoid The torque converter clutch (TCC) solenoid is used to control the apply and release of the TCC. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5531 Torque Converter Clutch Solenoid: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. Loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 7. Note: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5532 8. Disconnect the appropriate solenoid electrical connector. 1. Disconnect shift solenoids electrical connectors. 2. Disconnect the torque converter clutch (TCC) solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid electrical connector. 9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. CAUTION: Shift solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the appropriate solenoid(s). Installation 1. Install the new solenoid(s). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5533 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the torque converter clutch (TCC) solenoid electrical connector. 3. Connect the electrical pressure control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1. Install the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5534 2. Install the transmission fluid filter screw. 6. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. - Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. Connect the battery ground cable. 11. Fill the transmission to the proper fluid level and check for proper transmission operation. - Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Adjustments > Front Band Adjustment Band Apply Servo: Adjustments Front Band Adjustment Special Tools 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the shift cable. 1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the bracket. 4. CAUTION: Do not allow front band adjustment screw to back out. Band strut could fall out of position. CAUTION: Throw the locknut away. The locknut is not reusable for assembly. Remove and discard the locknut. 5. CAUTION: Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to the locknut seal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Adjustments > Front Band Adjustment > Page 5539 CAUTION: The servo must be installed prior to band adjustment. Note: The wrench will click at the specified torque. Install new locknut, do not tighten at this time. Tighten front band adjustment screw using the Band Adjuster Wrench Kit and back off front band adjustment screw exactly two (2) turns and hold that position. 6. Tighten the front band locknut. 1. Hold the front band adjustment screw stationary. 2. Tighten the front band locknut. 7. Install the shift cable. 1. Install the shift cable. 2. Install the shift cable to the manual control lever. 8. Lower the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Adjustments > Front Band Adjustment > Page 5540 Band Apply Servo: Adjustments Intermediate Band Adjustment 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Remove the shift cable. 1. Disconnect the shift cable from the manual control lever. 2. Remove the shift cable from the bracket. 4. Remove the digital transmission range (TR) sensor. 5. CAUTION: Do not allow the screw to back out. Band strut could fall out of position. CAUTION: Throw the locknut away. The locknut is not reusable for assembly. Remove and discard the locknut. 6. CAUTION: Install, but do not tighten, a new locknut on the screw. Apply petroleum jelly to the locknut seal. CAUTION: The intermediate servo must be installed prior to band adjustment. Note: The wrench will click at the specified torque. Install new locknut, do not tighten at this time. Tighten the screw using the Band Adjuster Wrench Kit and back off the screw exactly two (2) turns and hold that position. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Adjustments > Front Band Adjustment > Page 5541 7. Tighten the intermediate band locknut. 1. Hold the screw stationary. 2. Tighten the intermediate band locknut. 8. Install the digital TR sensor. 1. Position the digital TR sensor. 2. Loosely install the screws. 9. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Note: The manual lever must be in the neutral position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 10. Install the manual control outer lever. 1. Install the manual control outer lever. 2. Install the manual control outer lever nut. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Adjustments > Front Band Adjustment > Page 5542 11. Connect the digital transmission range (TR) sensor electrical connector. 12. Connect the shift cable. 1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever. 13. Verify that the shift cable is adjusted. 14. Lower the vehicle. 15. Connect the battery ground cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo Band Apply Servo: Service and Repair Front Servo Special Tools Removal 1. Disconnect the battery ground cable. 2. Raise and support vehicle. 3. Remove the shift cable. 1. Disconnect the shift cable from the manual control lever. 2. Remove the shift cable from the bracket. 4. Remove the digital transmission range (TR) sensor. 5. Remove the main control valve body. 6. Remove the three way catalytic converter (TWC). 7. Remove the transmission servo heat shield. 1. Remove the transmission servo heat shield nut. 2. Remove the transmission servo heat shield. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo > Page 5545 8. Remove the front band locknut and unscrew the front band adjusting screw. - Discard the front band locknut after removal. 9. CAUTION: Servo cover is under spring pressure. Using Servo Cover Compressor, remove the front band servo cover retaining ring. 1. Install the Servo Cover Compressor and compress the front band servo cover. 2. Remove the front servo cover retaining ring. - Slowly remove tension on the J-hook nut and remove the servo cover compressor. 10. CAUTION: Servo removal tool should be used to prevent damage to servo and bore. Use Servo Removal Tool to remove the front band servo cover, servo piston and servo piston spring. Insert Servo Removal Tool into the transmission case, locate on servo rod, and remove front band servo cover, servo piston and servo piston spring. Installation 1. Assemble the front band servo cover, front band servo piston, and the servo piston spring. 1. Install the front band servo piston into the front band servo cover. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo > Page 5546 2. Install the servo piston spring on the front band servo piston. 2. CAUTION: Do not damage O-ring during installation. Do not press servo cover and O-ring past relief hole in case, or O-ring damage may occur. Install the front band servo assembly into the transmission case. Lubricate the front band servo cover O-ring with petroleum jelly. 3. Use Servo Cover Compressor to install the front band servo cover retaining ring. 1. Install the Servo Cover Compressor and compress the front band servo cover. 2. Install the front servo cover retaining ring. 4. Install the main control valve body. 5. Adjust the front band. 6. Position the transmission servo heat shield on the transmission and install the nut. 7. Install the three way catalytic converter. 8. Install the shift cable. 1. Install the shift cable. 2. Install the shift cable to the manual control lever. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo > Page 5547 9. Install the digital transmission range (TR) sensor. 10. Lower the vehicle. 11. Connect the battery ground cable. 12. Fill the transmission to the proper fluid level and check for proper transmission operation. - Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON V specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo > Page 5548 Band Apply Servo: Service and Repair Intermediate Servo Special Tools Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Remove the shift cable. 1. Disconnect the shift cable from the manual control lever. 2. Remove the shift cable from the bracket. 4. Remove the digital transmission range (TR) sensor. 5. Remove the three way catalytic converter (TWC). 6. Remove the main control valve body. 7. Remove the transmission servo heat shield. 1. Remove the transmission servo heat shield nut. 2. Remove the transmission servo heat shield. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo > Page 5549 8. Remove the intermediate band locknut and unscrew the screw. - Discard the intermediate band locknut after removal. 9. CAUTION: Servo cover is under spring tension. Use caution when removing. Using Servo Cover Compressor, remove the intermediate band servo cover retaining ring. 1. Install the Servo Cover Compressor and compress the intermediate band servo cover. 2. Remove the intermediate servo cover retaining ring. - Slowly remove tension on the J hook nut and remove the servo cover compressor. 10. CAUTION: Servo removal tool should be used to prevent damage to the servo, servo cover, and bore. Use Servo Removal Tool to remove the intermediate band servo cover, intermediate band servo piston and servo piston spring. Insert Servo Removal Tool into the transmission case, and remove servo cover, intermediate band servo piston and servo piston spring. Installation 1. Assemble the intermediate band servo cover, intermediate band servo piston, and the servo piston spring. 1. Install the intermediate band servo piston into the intermediate band servo cover. 2. Install the servo piston spring on the intermediate band servo piston. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo > Page 5550 2. CAUTION: Do not damage O-ring during installation. Do not press servo cover and O-ring past relief hole in case, or O-ring damage may occur. Install the intermediate band servo piston assembly into the transmission case. Lubricate intermediate band servo cover O-ring with petroleum jelly. 3. Using Servo Cover Compressor, install the intermediate band servo cover retaining ring. 1. Install the Servo Cover Compressor and compress the intermediate band servo cover. 2. Install the intermediate servo cover retaining ring. 4. Adjust the intermediate band. 5. Install the main control valve body. 6. Install the digital transmission range (TR) sensor. 7. Position the transmission servo heat shield on the transmission and install the nut. 8. Install the shift cable. 1. Install the shift cable. 2. Install the shift cable to the manual control lever. 9. Install the three way catalytic converter. 10. Lower the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo > Page 5551 11. Connect the battery ground cable. 12. Fill the transmission to the proper fluid level and check for proper transmission operation. - Use MERCON (R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo > Page 5552 Band Apply Servo: Service and Repair Low/Reverse Servo Assembly Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Remove the transmission pan. 4. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 5. Remove the low/reverse band servo cover. 1. Remove the low/reverse band servo cover screws. 2. Remove the low/reverse band servo cover and gasket. Discard the low/reverse servo separator plate cover gasket. 6. Remove the low/reverse band servo piston and rod assembly. Installation 1. Clean and inspect the low/reverse band servo piston bore and the low/reverse band servo piston and rod. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo > Page 5553 2. Install the low/reverse band servo piston and rod. 1. Install the low/reverse band servo piston and rod assembly. 2. Install a new low/reverse band servo separator plate cover gasket. 3. Install the low/reverse band servo cover. - Loosely install the low/reverse band servo piston cover screws. 3. Tighten the servo cover screws in the sequence shown. 4. Install the transmission fluid filter. 1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw. 5. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align the transmission fluid pan. - Loosely install the transmission fluid pan screws. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Front Servo > Page 5554 6. Tighten the transmission fluid pan bolts. - Use a crisscross sequence to tighten the transmission fluid pan screws. 7. Lower the vehicle. 8. Connect the battery ground cable. 9. Fill the transmission to the proper fluid level and check for proper transmission operation. - Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON V specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Service and Repair Control Module: Service and Repair Removal 1. Remove the transmission control switch (TCS). 1. Remove the TCS cover. 2. Remove the TCS. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications Extension Housing: Specifications Extension housing screws and studs 27 - 39 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Service and Repair > Extension Housing Gasket - 4X2 Extension Housing: Service and Repair Extension Housing Gasket - 4X2 Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Note: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so they may be installed in their original alignment. Mark the rear driveshaft. 4. Remove the rear driveshaft. 1. Remove the bolts. 2. Remove the rear driveshaft. 5. Remove the nuts. 6. Raise and support the transmission. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Service and Repair > Extension Housing Gasket - 4X2 > Page 5563 7. Remove the transmission mount. 1. Remove the screws. 2. Remove the transmission mount. 8. Remove the extension housing screws and studs. 9. CAUTION: The parking pawl, parking pawl return spring and parking pawl shaft could fall out during removal of the extension housing. Remove the extension housing. Discard the extension housing gasket. Installation 1. Clean the extension housing and install new extension housing gasket. Make sure that the parking pawl, spring, and shaft are correctly installed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Service and Repair > Extension Housing Gasket - 4X2 > Page 5564 2. CAUTION: Make sure the parking lever actuating rod is correctly seated into the case parking rod guide cup. Install the extension housing. 1. Position the extension housing. 2. Install the extension housing screws. 3. Install the extension housing studs. 3. Install the transmission mount. 1. Position the transmission mount on the extension housing. 2. Install the transmission mount-to-extension housing screws. 4. Install the transmission mount into the crossmember and tighten the transmission mount nuts. 5. Note: Align the driveshaft with the marks made during removal to ensure correct balance. Align and install the rear driveshaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Service and Repair > Extension Housing Gasket - 4X2 > Page 5565 6. Install the bolts. 7. Lower the vehicle. 8. Connect the battery ground cable. 9. Fill the transmission to the proper fluid level and check for proper transmission operation. - Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Service and Repair > Extension Housing Gasket - 4X2 > Page 5566 Extension Housing: Service and Repair Extension Housing Gasket - 4X4 Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Note: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so they may be installed in their original alignment. Mark the rear driveshaft. 4. Remove the transfer case. 5. Remove the wire harness locators from the extension housing wire bracket. 6. Remove the transmission mount nuts. 7. Raise and support the transmission. 8. Remove the transmission mount. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Service and Repair > Extension Housing Gasket - 4X2 > Page 5567 1. Remove the transmission mount-to-extension housing screws. 2. Remove the transmission mount. 9. Remove the six extension housing screws and studs. 10. Note: The parking pawl, parking pawl return spring and parking pawl shaft may fall out during removal of the extension housing. Remove the extension housing. Discard the extension housing gasket. Installation 1. Clean the extension housing and install a new extension housing gasket. Make sure that the parking pawl, spring, and shaft are correctly installed. 2. CAUTION: Make sure the parking lever actuating rod is correctly seated into the case parking rod guide cup. Install the extension housing. Position the extension housing and install the six extension housing screws and studs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Service and Repair > Extension Housing Gasket - 4X2 > Page 5568 3. Install the transmission mount. 1. Position the transmission mount on the extension housing. 2. Install the screws. 4. Install the transmission mount into the crossmember and tighten the nuts. 5. Install the wire harness locators from the extension housing wire bracket. 6. Install the transfer case. 7. Note: Align the driveshaft with the marks made during removal to ensure correct balance. Align and install the rear driveshaft. 8. Install the bolts. 9. Connect the battery ground cable. 10. Fill the transmission to proper fluid level and check for proper transmission operation. - Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON V specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid .............................................................................................................................. ..................................................................... 10.0 qts Note: Approximately Dry Fill Capacity Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 5573 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ............................................................. MERCON V Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter Fluid - A/T: Service and Repair Fluid Pan, Gasket and Filter Fluid Pan, Gasket and Filter Removal 1. Raise and support the vehicle. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 2. Place a drain pan under the transmission fluid pan. 3. Drain transmission fluid. - Disconnect the LH three-way catalytic converter heated oxygen sensor connectors and remove the converter. - Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow fluid to drain. After fluid is drained, remove the front two transmission fluid pan screws. 4. Remove the transmission fluid pan. 1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 5576 5. Remove and discard the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. 7. Flush the transmission fluid cooler and transmission fluid cooler lines. Installation 1. CAUTION: Lubricate fluid filter O-rings with MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON (R) V or they may be damaged. Lube and install new O-rings onto the transmission fluid filter. Install a new transmission fluid filter. ^ Position transmission fluid filter on the main control valve body. 2. CAUTION: Make sure wire harness is not pinched under filter. Install transmission fluid filter screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 5577 3. Position the oil pan magnet in the transmission fluid pan. 4. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align the transmission fluid pan. ^ Loosely install the transmission fluid pan screws. 5. Tighten the transmission fluid pan screws. ^ Use a crisscross sequence to tighten the transmission fluid pan screws. 6. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 7. Lower the vehicle. 8. NOTE: When filling a dry transmission and converter, start with a minimum of 3.7 liters (4 quarts). Fill transmission to the correct fluid level and check for correct transmission operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 5578 ^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON(R) V. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 5579 Fluid - A/T: Service and Repair Drain and Refill W/Automated Equipment Transmission Fluid Drain and Refill-Automated Equipment Special Tool(s) Draining CAUTION: Use only clean automatic transmission fluid. Do not use any supplemental transmission fluid additives, treatments or cleaning agents. The use of these materials can affect the operation of the transmission, resulting in internal component failure. CAUTION: Always refer to the instructions supplied with the flush and fill machine. NOTE: This is a new procedure for draining and adding transmission fluid using a suitable transmission flush and fill machine. 1. With the vehicle in PARK, position on a hoist. 2. Use a suitable flush and fill machine to change the fluid. 3. When connecting the flush and fill machine, connect the machine to the fluid cooler tube after the fluid cooler on the cooler return tube. This will help remove any foreign material trapped in the fluid coolers. 4. Carry out the fluid exchange process. Refill 1. Use only clean automatic transmission fluid. 2. Once the fluid exchange has been completed, disconnect the flush and fill machine. Reconnect any disconnected fluid cooler tubes. 3. Lower the vehicle. 4. With the engine running and the transmission at normal operating temperature 66-77°C (150-170°F), check and adjust the transmission fluid level and check for any leaks. If fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until the correct level is achieved (fluid should be in the cross-hatched area of the fluid level indicator). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 5580 Fluid - A/T: Service and Repair Vehicles Not Equipped With Torque Converter Drain Plug Transmission Fluid Drain and Refill- Vehicles Not Equipped With Torque Converter Drain Plug Draining CAUTION: Use only clean automatic transmission fluid. Do not use any supplemental transmission fluid additives, treatments or cleaning agents. The use of these materials can affect the operation of the transmission, resulting in internal component failure. 1. With the vehicle in PARK, position on a hoist. 2. NOTE: If equipped, the transmission servo heat shield must be unclipped from the fluid pan rail and positioned aside for fluid pan removal. If equipped, loosen the nut and position the heat shield aside. 3. Place a drain pan under the transmission fluid pan. 4. Drain the transmission fluid. ^ Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow the fluid to drain. After the fluid is drained, remove the front two transmission fluid pan screws. 5. Remove the transmission fluid pan. 1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 5581 6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. Refill 1. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align the transmission fluid pan ^ Loosely install the transmission fluid pan screws. 2. Tighten the transmission fluid pan screws. ^ Tighten the transmission fluid pan screws in a crisscross sequence. 3. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 4. Lower the vehicle. 5. NOTE: When filling a dry transmission and converter, start with a minimum of 3.7 liters (4 quarts). With the engine running and the transmission at normal operating temperature 66-77°C (150-170°F), check and adjust the transmission fluid level and check for any leaks. If fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until the correct level is achieved (fluid should be in the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 5582 cross-hatched area of the fluid level indicator). 6. Apply the park brake, and start the engine. 7. Move the range selector lever through all the gears. 8. Check the transmission fluid level. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Specifications Fluid Filter - A/T: Specifications Transmission fluid filter screws 71 - 97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Specifications > Page 5586 Fluid Filter - A/T: Service and Repair Removal 1. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. Loosen the nut and position the heat shield out of the way. 2. Place a drain pan under the transmission fluid pan. 3. Drain transmission fluid. - Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front transmission fluid pan bolts. Pry the rear of the transmission fluid pan down and allow fluid to drain. After fluid is drained remove the front two transmission fluid pan bolts. 4. Remove the transmission fluid pan. 1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Specifications > Page 5587 5. Remove and discard the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. 7. Flush the transmission fluid cooler and transmission fluid cooler lines. Installation 1. CAUTION: Lubricate fluid filter O-rings with MERCON(R) V; Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON(R) V or they may be damaged. Lube and install new O-rings onto the transmission fluid filter. Install a new transmission fluid filter. Position transmission fluid filter on the main control valve body. 2. CAUTION: Make sure wire harness is not pinched under filter. Install transmission fluid filter screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Specifications > Page 5588 3. Position the oil pan magnet in the transmission fluid pan. 4. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align the transmission fluid pan. - Loosely install the transmission fluid pan screws. 5. Tighten the transmission fluid pan screws. - Use a crisscross sequence to tighten the transmission fluid pan screws. 6. Position the servo heat shield over the servos and clip it to the pan rail. 7. Lower the vehicle. 8. Note: When filling a dry transmission and converter start with a minimum of 3.7 liters (4 quarts). Fill transmission to the proper fluid level and check for proper transmission operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Specifications > Page 5589 - Use MERCON V; Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON V. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications Fluid Line/Hose: Specifications Transmission cooler lines to case connectors 26 - 32 ft.lb Transmission cooler line nut 18 - 23 ft.lb Transmission Auxiliary Fluid Cooler Hose Clamps 27 - 35 in.lb Transmission Fluid Cooler Tube Fitting To Radiator 10 - 16 ft.lb Transmission Fluid Cooler Tube to Case Fitting 18 - 23 ft.lb Transmission Cooler Lines Bracket Bolts 28 - 38 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications > Page 5593 Fluid Line/Hose: Service and Repair Removal 1. WARNING: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so may result in unexpected inflation or deflation of the air springs, which may result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the radiator air deflector. 1. Remove the bolts. 2. Remove the radiator air deflector. 3. Remove the nut, bolt and transmission cooler line bucket. 4. Remove the transmission fluid cooler tubes. 1. Remove the clips. 2. Disconnect the fittings. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications > Page 5594 - Use a backup wrench to hold the case fitting secure. 3. Remove the nut. 4. Remove the transmission fluid cooler tubes. Installation 1. Note: When a transmission fluid cooler tube is replaced, each replacement tube must be fabricated from the same size tube as the original. Shape a new transmission fluid cooler tube. Use the prior tube as a guide. - Install the appropriate fittings. 2. CAUTION: To prevent damage, make sure all plugs are removed from port openings before installing tubes. CAUTION: To prevent cross threading, all tube nuts must be hand started before being torqued to specification. Install the transmission fluid cooler tubes. 1. Install the clips. 2. Connect the tube fittings to the radiator. 3. Connect the tube fittings to the transmission. - Use a backup wrench to hold the case fitting secure. 4. Install the tube bracket nut. 5. Install the transmission fluid cooler tubes. 3. Install the nut, bolt, and transmission cooler line bracket. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications > Page 5595 4. Install the radiator air deflector. - Install the bolts. 5. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. 6. Fill transmission fluid to the proper level using the correct fluid and inspect for leaks. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - 5R44E/5R55E Part Level Change/Compatibility Fluid Pan: Technical Service Bulletins A/T - 5R44E/5R55E Part Level Change/Compatibility TSB 06-24-13 11/20/06 5R44E / 5R55E SERVICE PART LEVEL CHANGE / COMPATIBILITY FORD: 1997 Aerostar 1997-2001 Explorer 1997-2007 Ranger 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac MERCURY: 1998-2001 Mountaineer ISSUE Some vehicles equipped with a 5R44E or 5R55E automatic transmission may require repair of the transmission. This TSB is being published as informational only in order to avoid mix I match of incorrect service parts which will cause a fluid leak. Beginning with 8/29/2006 production, the 5R44E or 5R55E automatic transmission will have a new transmission case, fluid pan, a REUSABLE fluid pan gasket and new fluid pan screws. ACTION Follow the Service Tips. SERVICE TIPS NOTE DO NOT MIX AND MATCH PARTS OR LEAKAGE WILL OCCUR. NOTE THE NEW PAN GASKET IS NOT INCLUDED IN THE GASKET AND SEAL KIT. IT CAN ONLY BE ORDERED SEPARATELY. The 5R44E / 5R55E transmission pan gasket has been redesigned to be reusable if it is removed for a non-leak related transmission service concern. The gasket should be inspected for damage and cleaned, along with the mating surfaces, before reuse. The case and fluid pan rails have been redesigned to properly mate with the new gasket to eliminate fluid leaks. The new case, pan, and gasket maybe used to service past model transmissions from 1997. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - 5R44E/5R55E Part Level Change/Compatibility > Page 5600 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - 5R44E/5R55E Part Level Change/Compatibility > Page 5601 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - 5R44E/5R55E Part Level Change/Compatibility > Page 5602 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - 5R44E/5R55E Part Level Change/Compatibility > Page 5603 For 1997-2007 (early production) 4R44E I 5R44E and 5R55E when servicing the fluid pan gasket (7A191), the fluid pan (7A194) or the case (7005) do not mix and match old level and new level parts. The old level gasket, refer to Figure 3 (7A191) will be continued for past model applications. If replacing the older design level case, refer to Figure 1 (7005) and/or old lever fluid pan, refer to Figure 2 (7A194), ALL new components must be used. This includes the case (7005), refer to Figure 4, fluid pan (7A194), refer to Figure 5, fluid pan gasket (7A191), refer to Figure 6 and pan screws (W500212) (new torque specification - 7 lb-ft (10 N.m) refer to Figure 7. For correct part numbers refer to your parts catalogue. WARRANTY STATUS: Information Only Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > Page 5604 Fluid Pan: Specifications Pan Bolt Torque ................................................................................................................................... ...........................................................115-135 in. lbs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > Page 5605 Fluid Pan: Service and Repair Removal 1. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. Loosen the nut and position the heat shield out of the way. 2. Place a drain pan under the transmission fluid pan. 3. Drain transmission fluid. - Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front transmission fluid pan bolts. Pry the rear of the transmission fluid pan down and allow fluid to drain. After fluid is drained remove the front two transmission fluid pan bolts. 4. Remove the transmission fluid pan. 1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > Page 5606 5. Remove and discard the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. 7. Flush the transmission fluid cooler and transmission fluid cooler lines. Installation 1. CAUTION: Lubricate fluid filter O-rings with MERCON(R) V; Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON(R) V or they may be damaged. Lube and install new O-rings onto the transmission fluid filter. Install a new transmission fluid filter. Position transmission fluid filter on the main control valve body. 2. CAUTION: Make sure wire harness is not pinched under filter. Install transmission fluid filter screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > Page 5607 3. Position the oil pan magnet in the transmission fluid pan. 4. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align the transmission fluid pan. - Loosely install the transmission fluid pan screws. 5. Tighten the transmission fluid pan screws. - Use a crisscross sequence to tighten the transmission fluid pan screws. 6. Position the servo heat shield over the servos and clip it to the pan rail. 7. Lower the vehicle. 8. Note: When filling a dry transmission and converter start with a minimum of 3.7 liters (4 quarts). Fill transmission to the proper fluid level and check for proper transmission operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > Page 5608 - Use MERCON V; Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON V. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications Fluid Pump: Specifications Fluid pump screws 16 - 21 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations > Page 5616 Overdrive Indicator Lamp: Description and Operation Overdrive (O/D) Off The O/D OFF indicator illuminates when the transmission is locked out of O/D. This dual function indicator will also flash off and on if a transmission malfunction is detected. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Shift Indicator > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Shift Indicator > Component Information > Locations > Page 5620 Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the gearshift lever in the (D) position. - Rotate the gearshift lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (D) position). 3. Hang a 3.6 kg (8 lb.) weight on the gearshift lever. 4. Center the pointer in the middle of the (D) position. - Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer. 5. Remove the 3.6 kg (8 lb.) weight. 6. Carefully move the gearshift lever from detent to detent and compare with the transmission settings. - Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation TRANSMISSION CONTROL INDICATOR LAMP The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to Transmission Control Switch, PCM Inputs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Locations > Page 5627 Overdrive Indicator Lamp: Description and Operation Overdrive (O/D) Off The O/D OFF indicator illuminates when the transmission is locked out of O/D. This dual function indicator will also flash off and on if a transmission malfunction is detected. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair Parking Pawl: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. Loosen the nut and position the heat shield out of the way. 4. Remove the transmission fluid pan. 1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket. 5. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 5631 6. Remove wire loom guide and protector. - Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. 7. Disconnect the solenoid electrical connectors. 1. Disconnect shift solenoids SSB and SSD electrical connectors. 2. Disconnect the torque converter clutch (TCC) solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid electrical connector. 8. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. Remove the EPC, SSB, and SSD solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the EPC, SSB, and SSD solenoids. 9. CAUTION: Do not pry on the other wires or damage to the connector case surface may result. Disconnect the turbine shaft speed (TSS) sensor electrical connector from the transmission case (16 pin) electrical connector. 1. Disconnect the TSS sensor electrical connector. 2. Remove the TSS sensor wire locator. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 5632 10. CAUTION: Do not overstretch the retaining spring. Remove the transmission case (16 pin) electrical connector retaining spring. 11. CAUTION: Do not damage the connector or harness. Remove the transmission case (16 pin) electrical connector. Compress the tabs on the connector. - Push the connector out of the transmission case. 12. Remove the manual control valve detent lever spring. 1. Remove the screw. 2. Remove the spring. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 5633 13. CAUTION: To avoid damage, make sure the wrench does not strike the manual valve inner lever pin. Remove the manual valve inner lever nut. 14. Remove the manual valve inner lever and parking lever actuating rod. 15. Note: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so they may be installed in their original alignment. Mark the rear driveshaft. 16. Remove the rear driveshaft. 1. Remove the bolts. 2. Remove the rear driveshaft. 17. If equipped, remove the transfer case. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 5634 18. Note: If damage is found to the parking gear, the transmission must be removed and disassembled. Note: The parking pawl, parking pawl return spring and parking pawl shaft may fall out during removal of the extension housing. Remove the extension housing and discard the extension housing gasket. 19. Inspect the parking pawl, parking pawl return spring and the parking pawl shaft. - Replace if required. Installation 1. CAUTION: Make sure the parking lever actuating rod is correctly seated into the case parking rod guide cup. Verify that the output shaft is locked in the PARK position. Align the flats of the manual valve inner lever with the flats on the manual control lever shaft. Install the manual valve inner lever and parking lever actuating rod onto the manual control lever shaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 5635 2. CAUTION: Do not bend the manual valve inner lever pin. Install the manual valve inner lever nut. 3. Install the manual valve detent spring. 4. Clean the extension housing and install a new extension housing gasket. Make sure that the parking pawl, spring, and shaft is correctly installed. 5. CAUTION: Make sure the parking lever actuating rod is correctly seated into the case parking rod guide cup. Install the extension housing. 1. Position the extension housing, 2. Install the extension housing screws. 3. Install the extension housing stud. 6. If equipped, install the transfer case. 7. Note: Align the drive shaft with the marks made during removal to ensure correct balance. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 5636 Install the rear driveshaft bolts. 8. Note: Make sure the tab is in the lock position. Note: Install new O-rings on the transmission case (16 pin) electrical connector. Install the transmission case (16 pin) electrical connector. Lubricate the transmission case (16 pin) electrical connector O-rings with petroleum jelly. 9. Press the transmission case (16 pin) electrical connector through the case until a click is heard. 10. CAUTION: Align the slot on the TSS sensor electrical connector with the slot in the 16 pin case connector. Install the TSS sensor wire. 1. Install the TSS sensor wire into (16 pin) electrical connector. 2. Install the TSS sensor wire into locator. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 5637 11. CAUTION: Do not overstretch the retaining spring. Install the transmission case (16 pin) electrical connector retaining spring. 12. Install the EPC, SSD, and SSB solenoids. 13. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 5638 14. Connect the TCC, SSD, SSB, and EPC solenoid electrical connectors. 15. CAUTION: Excessive pressure may break the retaining pins. Install the wire loom guide and protector. Align the retaining pins to the holes in the solenoid clamps and gently press in the wire loom guide and protector. 16. Install the transmission fluid pan. 1. Install a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align the transmission fluid pan. - Loosely install the transmission fluid pan screws. 17. Using a crisscross sequence, tighten the transmission fluid pan screws. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair > Page 5639 18. Position the servo heat shield over the servos and clip it to the pan rail. 19. Lower the vehicle. 20. Connect the battery ground cable. 21. Fill transmission to proper fluid level and check for proper transmission operation. - Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON V specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations Pressure Regulating Solenoid: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5643 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5644 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5645 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Pressure Regulating Solenoid: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5648 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5649 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5650 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5651 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5652 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5653 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5654 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5655 Pressure Regulating Solenoid: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5656 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5657 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5658 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5659 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5660 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5661 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5662 Diagram 29-4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5663 Pressure Regulating Solenoid: Description and Operation Electronic Pressure Control (EPC) Solenoid The electronic pressure control (EPC) solenoid is a variable force style (VFS) solenoid. The VFS type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve. The powertrain control module varies the current to the EPC solenoid. This action causes the solenoid to regulate transmission line pressure and line modulator pressure. This is done by producing resisting forces to the main regulator and line modulator circuits. These two solenoids control clutch application pressures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5664 Pressure Regulating Solenoid: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. Loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 7. Note: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5665 8. Disconnect the appropriate solenoid electrical connector. 1. Disconnect shift solenoids electrical connectors. 2. Disconnect the torque converter clutch (TCC) solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid electrical connector. 9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. CAUTION: Shift solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the appropriate solenoid(s). Installation 1. Install the new solenoid(s). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5666 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the torque converter clutch (TCC) solenoid electrical connector. 3. Connect the electrical pressure control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1. Install the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5667 2. Install the transmission fluid filter screw. 6. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. - Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. Connect the battery ground cable. 11. Fill the transmission to the proper fluid level and check for proper transmission operation. - Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair Control Module: Service and Repair Removal 1. Remove the transmission control switch (TCS). 1. Remove the TCS cover. 2. Remove the TCS. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T Seals and Gaskets: Service and Repair Extension Housing Seal, A/T Special Tools Special Tools Removal 1. Raise and support the vehicle. 2. Note: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so they may be installed in their original alignment. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5676 Mark the rear driveshaft. 3. Remove the rear driveshaft. 1. Remove the rear driveshaft bolts. 2. Remove the rear driveshaft. 4. Using the Converter Oil Seal Remover and Impact Slide Hammer, remove the extension housing seal. 5. CAUTION: Use the extension housing bushing remover carefully so that the seal area is not damaged. Remove extension housing bushing. 1. Install Housing Bushing Remover. 2. Remove extension housing bushing. Installation 1. CAUTION: The lube hole in the extension housing bushing must be aligned with the lube groove in the extension housing. This groove is located at the 3 o'clock position when viewed from the rear. Note: Inspect the counterbore of the extension housing for burrs. Remove any burrs from the extension housing counterbore with an oil stone. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5677 Position the extension housing bushing into the extension housing. 2. CAUTION: The tool will bottom when bushing is in the proper position. Use the Housing Bushing Replacer to install the extension housing bushing. 3. Position new extension housing seal with drain hole in the 6 o'clock position. 4. Use the Extension Housing Seal Replacer to install the extension housing seal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5678 5. Note: Inspect the driveshaft slip-yoke for wear and damage. Replace if required. Align the drive shaft with the marks made during removal to ensure correct balance. 6. Install the rear driveshaft bolts. 7. Lower the vehicle. 8. Fill the transmission to the proper fluid level and check for proper transmission operation. - Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON V specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5679 Seals and Gaskets: Service and Repair Shift Shaft Seal Special Tools Removal 1. Disconnect the battery ground cable. 2. Raise and-support vehicle. 3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. Loosen the nut and position the heat shield out of the way. 4. Note: It is not necessary to remove the transmission fluid filter to perform this procedure. Remove the transmission fluid pan. 5. Remove the digital transmission range (TR) sensor. 6. Remove the manual control valve detent lever spring. 1. Remove the manual control valve detent lever spring screw. 2. Remove the manual control valve detent lever spring. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5680 7. CAUTION: Do not damage the valve inner lever pin. Remove the manual valve inner lever nut. 8. Separate the manual valve inner lever and the parking lever actuating rod. 9. CAUTION: Do not damage the case fluid pan rail. Remove the manual control lever shaft spring pin. Tap lightly on each side of the manual control lever shaft spring pin with a drift punch. - Pry the spring pin out of its bore. 10. Remove the manual control lever shaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5681 11. CAUTION: Do not damage the bore. Remove the manual control lever shaft seal. Installation 1. Using the special tool, install the manual control lever shaft seal. - Lubricate the manual control lever shaft seal with petroleum jelly. 2. Install the manual control lever shaft. 3. CAUTION: Use care not to damage the fluid pan rail surface when installing the retaining pin. Align the manual control lever shaft alignment groove with the manual control lever shaft spring pin bore in the transmission case. Tap the manual control lever shaft spring pin into the transmission case. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5682 4. Align flats of the manual valve inner lever with flats on the manual control lever shaft. Install the manual valve inner lever and parking lever actuating rod onto the manual control lever shaft. 5. CAUTION: Do not bend the manual valve inner lever pin. Install the manual valve inner lever nut. 6. CAUTION: Park pawl actuating rod must be properly installed into parking pawl and guide cup located in extension housing. Verify park linkage function. Verify that the output shaft is locked in the PARK position. 7. Install the manual valve detent spring. 8. Install the transmission fluid pan with new pan gasket. 9. Position the servo heat shield over the servos and clip it to the pan rail. 10. Install the digital transmission range (TR) sensor. 11. Lower the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5683 12. Connect the battery ground cable. 13. Fill the transmission to proper level and check for proper transmission operation. - Use MERCON V at Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON V. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital transmission range (TR) sensor screws 71 - 97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5691 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5692 Digital Transmission Range Sensor: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5693 Digital Transmission Range Sensor: Service and Repair Special Tools Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the shift cable. 1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the bracket. 4. Disconnect the digital transmission range (TR) sensor electrical connector. 5. Remove the manual control outer lever nut and manual control outer lever. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5694 6. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor. 1. Position the digital TR sensor. 2. Loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Note: The manual lever must he in the neutral position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever. 1. Install the manual control outer lever. 2. Install the manual control outer lever nut. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5695 4. Connect the digital transmission range (TR) sensor electrical connector. 5. Connect the shift cable. 1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. Connect the battery ground cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Turbine shaft speed (TSS) sensor screw 71 - 97 in.lb Output shaft speed sensor (OSS) sensor screw 71 - 97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 5699 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Speed 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5702 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5703 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5704 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5705 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5706 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5707 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5708 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5709 Transmission Speed Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5710 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5711 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5712 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5713 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5714 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5715 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5716 Transmission Speed Sensor: Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5717 Diagram 29-4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5718 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Transfer Case - Automatic Shift Transmission Speed Sensor: Service and Repair Transfer Case - Automatic Shift Output Shaft Speed Sensor-Front Removal 1. Remove the transfer case shift motor. 2. Remove the front output shaft speed sensor. 1. Remove the bolt. 2. Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Output Shaft Speed Sensor-Rear Removal Warning: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. 1. Raise and support vehicles. 2. Disconnect the electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Transfer Case - Automatic Shift > Page 5721 3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector. 1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover. 4. Remove the bolt and the sensor. Installation 1. Caution: Make sure the sensor seats flat against the boss To install, reverse the removal procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Transfer Case - Automatic Shift > Page 5722 Transmission Speed Sensor: Service and Repair 5R55E Removal 1. Raise and support the vehicle. 2. Disconnect output shaft speed (OSS) sensor electrical connector. 3. Remove OSS sensor. 1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission. - Inspect the OSS sensor O-ring for damage. If damaged, replace the O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Transfer Case - Automatic Shift > Page 5723 2. Connect OSS sensor electrical connector. 3. Lower the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations The Transmission Fluid Temperature Sensor is located on the main control body wiring harness assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5729 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5730 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5731 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5732 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5733 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5734 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5735 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5736 Transmission Temperature Sensor/Switch: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5737 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5738 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5739 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5740 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5741 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5742 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5743 Diagram 29-4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 5744 Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference voltage signal. The resistance in the TFT varies with temperature. The powertrain control module (PCM) monitors the voltage signal across the TFT, and uses this information to determine the transmission fluid temperature. The TFT is located on the main control body wiring harness assembly. The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation and electronic pressure control (EPC). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications Shift Lock Actuator Bolts 62.5-98 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5749 Shift Interlock Solenoid: Service and Repair Removal 1. Remove the steering column assembly. 2. Remove the insert plate and shift lock actuator. 1. Remove the bolts. 2. Remove the insert plate and shift lock actuator. 3. Note: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced. Remove the insert plate from the shift lock actuator. Remove and discard the shift lock actuator clip. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations Shift Solenoid: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Page 5753 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Page 5754 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Page 5755 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5758 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5759 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5760 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5761 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5762 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5763 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5764 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5765 Shift Solenoid: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5766 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5767 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5768 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5769 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5770 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5771 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5772 Diagram 29-4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 5773 Shift Solenoid: Description and Operation Shift Solenoids A, B, C, and D Four On/Off shift solenoids allow the powertrain control module to control shift scheduling. - The solenoids are two-way, normally open style. - The shift solenoids (SSA, SSB, SSC, and SSD) provide gear selection by controlling the pressures of the shift valves. - SSD is also used to apply and release the coast clutch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 5774 Shift Solenoid: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. Loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 7. Note: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 5775 8. Disconnect the appropriate solenoid electrical connector. 1. Disconnect shift solenoids electrical connectors. 2. Disconnect the torque converter clutch (TCC) solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid electrical connector. 9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. CAUTION: Shift solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the appropriate solenoid(s). Installation 1. Install the new solenoid(s). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 5776 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the torque converter clutch (TCC) solenoid electrical connector. 3. Connect the electrical pressure control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1. Install the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Page 5777 2. Install the transmission fluid filter screw. 6. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. - Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. Connect the battery ground cable. 11. Fill the transmission to the proper fluid level and check for proper transmission operation. - Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair Shifter A/T: Service and Repair Removal 1. Remove the ignition switch. 2. Remove the upper steering column shroud. 3. Remove the gearshift lever. 1. Disconnect the shift control selector lever harness connector. 2. Remove and discard the gearshift lever pin. 3. Remove the gearshift lever. Installation 1. Note: The gearshift lever pin must be replaced whenever removed. Follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications Shift Cable: Specifications Shift Cable Bracket 15-21 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 5785 Shift Cable: Adjustments 1. Place the gearshift lever in the (D) position and hang a 3.6 kg (8 lb.) weight on the gearshift lever. 2. Raise and support the vehicle. 3. Disconnect the transmission shift cable from the manual control lever. 4. Pull out the transmission shift cable adjustment lock tab on the shift cable body. 5. Place the manual control lever in the (D) position. 1. Place the manual control lever in the first gear position. Rotate the manual control lever forward until travel stops. 2. Move the manual control lever back two detents to the (D) position. 6. Connect the transmission shift cable to the manual control lever. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 5786 7. Push in the transmission shift cable adjustment lock tab on the shift cable body. 8. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. 9. Remove the 3.6 kg (8 lb.) weight. 10. CAUTION: Do not adjust the transmission shift cable in any position other than (D). Verify that the vehicle will start in P or N and that backup lamps illuminate in R. If not, repeat Steps 1 through 7 and perform a digital transmission range sensor alignment. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 5787 Shift Cable: Service and Repair Removal 1. Disconnect the transmission shift cable from the steering column. 1. Disconnect the shift cable from the transmission column shift selector tube. 2. Disconnect the shift cable from the steering column bracket. 2. Push the rubber grommet and transmission shift cable through the bulkhead. 3. Raise and support the vehicle. 4. Remove the transmission shift cable from the automatic transmission. 1. Disconnect the shift cable from the manual control lever. 2. Depress lock tabs to release shift cable and disconnect the shift cable from the shift cable bracket. 5. Remove the transmission shift cable bracket from the automatic transmission. 1. Remove the bolt. 2. Remove the transmission shift cable bracket. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 5788 1. Note: The manual lever must be in the O/D position. Follow the removal procedure in reverse order. Adjust the transmission shift cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Bolt 80-97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5792 Torque Converter Clutch Solenoid: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5793 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5794 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5795 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5798 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5799 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5800 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5801 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5802 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5803 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5804 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5805 Torque Converter Clutch Solenoid: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5806 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5807 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5808 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5809 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5810 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5811 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5812 Diagram 29-4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5813 Torque Converter Clutch Solenoid: Description and Operation Torque Converter Clutch (TCC) Solenoid The torque converter clutch (TCC) solenoid is used to control the apply and release of the TCC. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5814 Torque Converter Clutch Solenoid: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. Loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 7. Note: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5815 8. Disconnect the appropriate solenoid electrical connector. 1. Disconnect shift solenoids electrical connectors. 2. Disconnect the torque converter clutch (TCC) solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid electrical connector. 9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. CAUTION: Shift solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the appropriate solenoid(s). Installation 1. Install the new solenoid(s). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5816 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the torque converter clutch (TCC) solenoid electrical connector. 3. Connect the electrical pressure control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1. Install the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5817 2. Install the transmission fluid filter screw. 6. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. - Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. Connect the battery ground cable. 11. Fill the transmission to the proper fluid level and check for proper transmission operation. - Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Cover > Component Information > Specifications Torque Converter Cover: Specifications Converter housing screws 27-39 ft.lb Converter housing-to-engine screws 30-41 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 SOHC VIN K SFI (2001)) 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 5825 ^ 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 SOHC VIN K SFI (2001)) 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 5826 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 5827 Transmission Cooler: Specifications Transmission Auxiliary Fluid Cooler Bolts 45 - 62 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 5828 Transmission Cooler: Service and Repair Removal 1. Shut off the air suspension if equipped. 2. Disconnect the battery cables. 3. Raise and support the vehicle. 4. Remove the radiator air deflector. 1. Remove the bolts. 2. Remove the radiator air deflector. 5. Place a drain pan under the transmission auxiliary fluid cooler. 6. Note: On 5.0L, the radiator must be loosened to provide access for removing the upper transmission fluid cooler screw. Loosen the two upper radiator hold down screws. 7. Remove the transmission auxiliary fluid cooler. 1. Disconnect the hoses. 2. Remove the bolts. 3. Remove the transmission auxiliary fluid cooler. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 5829 1. Follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation TRANSMISSION CONTROL INDICATOR LAMP The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to Transmission Control Switch, PCM Inputs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Description and Operation Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications Transmission Mount: Specifications Transmission mount nuts to crossmember 64 - 81 ft.lb Transmission mount-to-extension housing screws 64 - 81 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications > Page 5839 Transmission Mount: Service and Repair Removal 1. Note: 4x2 procedure shown. 4x4 similar, front drive shaft will need to be removed. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Note: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so they may be installed in their original alignment. Mark the rear driveshaft. 4. Remove the rear driveshaft. 1. Remove the bolts. 2. Remove the rear driveshaft. 5. Remove the transmission mount nuts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications > Page 5840 6. Raise and support the transmission. 7. Remove the transmission mount. 1. Remove the screws. 2. Remove the transmission mount. Installation 1. Install the transmission mount. 1. Position the transmission mount on the extension housing. 2. Install the transmission mount-to-extension housing screws. 2. Install the transmission mount into the crossmember and tighten the nuts. 3. Note: Align the driveshaft with the marks made during removal to ensure correct balance. Align and install the rear driveshaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications > Page 5841 4. Install the bolts. 5. Lower the vehicle. 6. Connect the battery ground cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital transmission range (TR) sensor screws 71 - 97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5845 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5846 Digital Transmission Range Sensor: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5847 Digital Transmission Range Sensor: Service and Repair Special Tools Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the shift cable. 1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the bracket. 4. Disconnect the digital transmission range (TR) sensor electrical connector. 5. Remove the manual control outer lever nut and manual control outer lever. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5848 6. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor. 1. Position the digital TR sensor. 2. Loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Note: The manual lever must he in the neutral position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever. 1. Install the manual control outer lever. 2. Install the manual control outer lever nut. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5849 4. Connect the digital transmission range (TR) sensor electrical connector. 5. Connect the shift cable. 1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. Connect the battery ground cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Turbine shaft speed (TSS) sensor screw 71 - 97 in.lb Output shaft speed sensor (OSS) sensor screw 71 - 97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 5853 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Speed 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5856 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5857 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5858 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5859 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5860 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5861 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5862 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5863 Transmission Speed Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5864 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5865 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5866 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5867 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5868 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5869 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5870 Transmission Speed Sensor: Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5871 Diagram 29-4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5872 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Transfer Case - Automatic Shift Transmission Speed Sensor: Service and Repair Transfer Case - Automatic Shift Output Shaft Speed Sensor-Front Removal 1. Remove the transfer case shift motor. 2. Remove the front output shaft speed sensor. 1. Remove the bolt. 2. Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Output Shaft Speed Sensor-Rear Removal Warning: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. 1. Raise and support vehicles. 2. Disconnect the electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Transfer Case - Automatic Shift > Page 5875 3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector. 1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover. 4. Remove the bolt and the sensor. Installation 1. Caution: Make sure the sensor seats flat against the boss To install, reverse the removal procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Transfer Case - Automatic Shift > Page 5876 Transmission Speed Sensor: Service and Repair 5R55E Removal 1. Raise and support the vehicle. 2. Disconnect output shaft speed (OSS) sensor electrical connector. 3. Remove OSS sensor. 1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission. - Inspect the OSS sensor O-ring for damage. If damaged, replace the O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Transfer Case - Automatic Shift > Page 5877 2. Connect OSS sensor electrical connector. 3. Lower the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations The Transmission Fluid Temperature Sensor is located on the main control body wiring harness assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5883 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5884 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5885 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5886 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5887 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5888 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5889 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5890 Transmission Temperature Sensor/Switch: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5891 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5892 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5893 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5894 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5895 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5896 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5897 Diagram 29-4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 5898 Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference voltage signal. The resistance in the TFT varies with temperature. The powertrain control module (PCM) monitors the voltage signal across the TFT, and uses this information to determine the transmission fluid temperature. The TFT is located on the main control body wiring harness assembly. The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation and electronic pressure control (EPC). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 03-22-10 > Nov > 03 > A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set Valve Body: Customer Interest A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set Article No. 03-22-10 11/10/03 TRANSMISSION - 4R44E - 4R55E - 5R44E - 5R55E - LOW LINE PRESSURE READING AT WIDE OPEN THROTTLE (WOT) - POSSIBLE DIAGNOSTIC TROUBLE CODES P0732, P0733, P1762 - VEHICLES BUILT BEFORE 12/1/2001 FORD: 1995-2001 EXPLORER 1995-2002 RANGER 1996-1997 AEROSTAR 2000-2002 EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC MERCURY: 1997-2001 MOUNTAINEER This article supersedes TSB's 03-11-9, 02-13-8 and 02-08-2 to update the model coverage. ISSUE Some vehicles built prior to 12/1/2001 may exhibit the following shift and engagement conditions: ^ No 2nd Gear ^ No 3rd Gear ^ No Engine Braking In Manual 1st. Out of specification pressures controlled by the transmission main control valve body separator plate may be the cause. ACTION Verify the condition, the main control valve body separator plate may need to be updated to the latest level. Refer to the following Service Procedure for details. SERVICE PROCEDURE Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 03-22-10 > Nov > 03 > A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set > Page 5907 CAUTION A NEW SEPARATOR 7Z490 MUST BE USED WHEN INSTALLING THE SPECIAL SERVICE KIT 7M203 OR ADDITIONAL TRANSMISSION DAMAGE MAY OCCUR. REFER TO THE PARTS APPLICATION CHART IN THIS ARTICLE FOR CORRECT SEPARATOR PLATE PART LISTING. 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. NOTE AN IN-LINE SERVICE FILTER IS NOT REQUIRED TO BE ADDED OR REPLACED FOR THIS TSB. 1. Verify that one or more of the following conditions exist. ^ Low Line Pressure While In Drive At WOT ^ No 2nd And/Or No 3rd Gear Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 03-22-10 > Nov > 03 > A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set > Page 5908 ^ No Engine Braking In Manual 1st ^ DTC P0732, P0733 Or P1762 2. Install kit (3L5Z-7M203-JA) to update the main control valve body assembly, refer to the installation procedures found in the kit. 3. Reinstall the main control by continuing to follow the installation steps listed in the Workshop Manual, in-vehicle service, main control valve body. 4. After completing the procedure, verify the condition has been corrected. 5. Clear all DTCs. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-11-9, 02-13-8 02-08-2 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 032210A Replace Separator Plate 2.8 Hrs. And Update Main Control Valve Body (Includes Time To Remove And Install Main Control Valve Body And Diagnosis) DEALER CODING CONDITION BASIC PART NO. CODE D100 D8 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 03-22-10 > Nov > 03 > A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set Valve Body: All Technical Service Bulletins A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set Article No. 03-22-10 11/10/03 TRANSMISSION - 4R44E - 4R55E - 5R44E - 5R55E - LOW LINE PRESSURE READING AT WIDE OPEN THROTTLE (WOT) - POSSIBLE DIAGNOSTIC TROUBLE CODES P0732, P0733, P1762 - VEHICLES BUILT BEFORE 12/1/2001 FORD: 1995-2001 EXPLORER 1995-2002 RANGER 1996-1997 AEROSTAR 2000-2002 EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC MERCURY: 1997-2001 MOUNTAINEER This article supersedes TSB's 03-11-9, 02-13-8 and 02-08-2 to update the model coverage. ISSUE Some vehicles built prior to 12/1/2001 may exhibit the following shift and engagement conditions: ^ No 2nd Gear ^ No 3rd Gear ^ No Engine Braking In Manual 1st. Out of specification pressures controlled by the transmission main control valve body separator plate may be the cause. ACTION Verify the condition, the main control valve body separator plate may need to be updated to the latest level. Refer to the following Service Procedure for details. SERVICE PROCEDURE Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 03-22-10 > Nov > 03 > A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set > Page 5914 CAUTION A NEW SEPARATOR 7Z490 MUST BE USED WHEN INSTALLING THE SPECIAL SERVICE KIT 7M203 OR ADDITIONAL TRANSMISSION DAMAGE MAY OCCUR. REFER TO THE PARTS APPLICATION CHART IN THIS ARTICLE FOR CORRECT SEPARATOR PLATE PART LISTING. 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. NOTE AN IN-LINE SERVICE FILTER IS NOT REQUIRED TO BE ADDED OR REPLACED FOR THIS TSB. 1. Verify that one or more of the following conditions exist. ^ Low Line Pressure While In Drive At WOT ^ No 2nd And/Or No 3rd Gear Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 03-22-10 > Nov > 03 > A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set > Page 5915 ^ No Engine Braking In Manual 1st ^ DTC P0732, P0733 Or P1762 2. Install kit (3L5Z-7M203-JA) to update the main control valve body assembly, refer to the installation procedures found in the kit. 3. Reinstall the main control by continuing to follow the installation steps listed in the Workshop Manual, in-vehicle service, main control valve body. 4. After completing the procedure, verify the condition has been corrected. 5. Clear all DTCs. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-11-9, 02-13-8 02-08-2 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 032210A Replace Separator Plate 2.8 Hrs. And Update Main Control Valve Body (Includes Time To Remove And Install Main Control Valve Body And Diagnosis) DEALER CODING CONDITION BASIC PART NO. CODE D100 D8 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5916 Valve Body: Specifications Main control valve body screws 71 - 97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5917 Valve Body: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5918 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Special Tools Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5921 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5922 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5923 Disassembly Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5924 1. CAUTION: The SSC solenoid may pop out of its bore. This may damage the solenoid. Remove the SSA and the SSC clamp and SSA and SSC solenoid. 1. Remove the solenoid clamp screw. 2. Remove the solenoid clamp. 3. Remove the SSA and SSC solenoids. 2. CAUTION: The torque converter clutch solenoid (TCC) solenoid may pop out of its bore. This may damage the solenoid. CAUTION: The converter modulator valve may come out after the TCC solenoid. This may cause damage to the valve. Remove the SSB, SSD, torque converter clutch solenoid, and the EPC solenoid. 1. Remove the solenoid clamp screw. 2. Remove the solenoid clamp. 3. Remove the SSB, SSD, torque converter clutch solenoid and the EPC solenoids. 3. Rotate the main control valve body so that the main control to case gasket is facing up. 4. CAUTION: Valves may come out when rotating the main control valve body. CAUTION: The extension housing lube orifice and relief valves may stick to the separator plate. Note: Discard the main control to case gasket. Remove the valve body separator plate screws. 1. Remove the main control to case gasket and discard. 2. Remove the valve body separator plate screws. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5925 5. Remove valve body separator plate and main control to Separating plate gasket. 1. Remove valve body separator plate. 2. Remove main control to separator plate gasket and discard. 6. Remove the extension housing lube orifice and the metal silver electronic pressure control (EPC) limit relief valve and spring. 1. Remove the extension housing lube orifice. 2. Remove the silver metal EPC limit relief valve and spring. 7. Remove the black plastic converter relief valve and spring. 8. Remove the electronic pressure control (EPC) limit circuit screen. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5926 9. Remove the four main control valve body check balls. Assembly 1. CAUTION: Do not lose parts when cleaning or servicing. Thoroughly clean all parts in solvent and blow dry with mo1sture free compressed air. 2. CAUTION: Do not stone, file, or sand the valves. This will remove the anodized finish and may result in further main control or transmission damage. After cleaning the main control valve body, carry out the following: Inspect all valve and plug bores for scoring or burrs. - Check all fluid passages for obstructions. - Inspect all valves and plugs for burrs. - Inspect all mating surfaces for burrs or d1stortion. - Inspect all springs for d1stortion. - Check all valves and plugs for free movement in their respective bores. Valves and plugs, when dry, must fall from their own weight into their respective bores. - Roll the manual valve on a flat surface to cheek for a bent condition. 3. Clean and inspect the EPC solenoid screens. 4. Remove and replace all shift solenoid O-rings. 5. Clean and inspect the torque converter clutch solenoid. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5927 6. CAUTION: Make sure that the screen is properly located. Clean and inspect the electronic pressure control (EPC) limit circuit screen. Install the EPC limit circuit screen. 7. Install the four main control valve body check balls. 8. CAUTION: The springs and valves are not interchangeable. Damage to transmission may occur. Install the dark color plastic converter relief valve and spring. 9. Note: The springs and valves are not interchangeable. Install the extension housing lube orifice and the metal silver electronic pressure control (EPC) limit relief valve and spring. 1. Install the extension housing lube orifice. 2. Install the silver metal EPC limit relief valve and spring. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5928 10. Note: Apply petroleum jelly on the valve body separator plate to hold the main control to separator plate gasket in place. Note: Use new separator plate main control to separator plate gasket on installation. Install the main control valve body separator plate and gasket to the main control. 1. Position the main control valve body separator plate to the main control gasket and install separator plate to main control valve body. 2. Install, do not tighten, the three screws. 11. Install the Valve Body Aligner into the main control valve body. 1. Install the Valve Body Aligner (0.248). 2. Install the Valve Body Aligner (0.235). 12. Tighten the screws. 13. Note: Apply petroleum jelly on the separator plate surface to hold the gasket in place. Note: Use new separator plate gasket on installation. Install new main control to case gasket. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5929 14. Remove the Valve Body Aligner from the main control valve body. 1. Remove the Valve Body Aligner (0.248). 2. Remove the Valve Body Aligner (0.235). 15. Rotate the main control valve body so the valve body separator plate is facing down. 16. CAUTION: All solenoid electrical connectors must face upward on installation. Note: All shift solenoids are interchangeable. Note: If the TCC valve came out during disassembly, use caution when installing the torque converter clutch solenoid. Install the SSB, SSD, TCC and EPC solenoids. 1. Install the TCC solenoid. 2. Install the SUB and SSD solenoids. 3. Install the EPC solenoid. 17. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Install the solenoid clamp and the screw. 1. Position the solenoid clamp on the main control valve body. 2. Install the screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5930 18. CAUTION: The shift solenoid electrical terminals must face up on installation. Note: The shift solenoids are interchangeable. Install the SSA and the SSC shift solenoids. 19. Install the solenoid clamp and the screw. 1. Position the solenoid clamp on the main control valve body. 2. Install the screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5931 Valve Body: Service and Repair Removal and Installation Special Tools Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Place a drain pan under the transmission fluid pan. 4. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. Loosen the nut and position the heat shield out of the way. 5. Drain transmission fluid. Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front transmission fluid pan bolts. Pry the rear of the transmission fluid pan down and allow fluid to drain. After fluid is drained remove the front two transmission fluid pan bolts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5932 6. Note: If a transmission has been disassembled to replace worn or damaged parts and the valves in the main control valve body stick repeatedly from foreign material, the torque converter must be removed and cleaned by using a suitable torque converter/fluid cooler cleaner. Remove the transmission fluid pan. 1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket. 7. Remove and discard the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 8. Unclip main control valve body wire harness. - Lift up on wire harness guide and protector and disengage the retaining pins from the solenoid clamps. 9. Disconnect the six solenoid electrical connectors. 1. Disconnect the SSA, SSB, SSC and SSD electrical connectors. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5933 2. Disconnect the torque converter clutch (TCC) solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid electrical connector. 10. Remove the manual control valve detent lever spring. 1. Remove the manual control valve detent lever spring screw. 2. Remove the manual control valve detent lever spring. 11. Remove the low/reverse servo. 1. Remove the low/reverse servo cover screws. 2. Remove the low/reverse band servo cover and gasket. Discard the low/reverse servo separator plate cover gasket. 12. Remove the low/reverse band servo piston and rod. 13. CAUTION: Support the main control valve body. Do not remove the two (gold) screws specified. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5934 14. CAUTION: Support the main control valve body. Remove the screws. 15. Remove the main control valve body. Installation 1. Install the Valve Body Aligner into the transmission case. 1. Install the Valve Body Aligner (0.248). 2. Install the Valve Body Aligner (0.235). 2. Note: Make sure main control to case gasket is properly aligned. Install new main control to case gasket. 3. Position the main control valve body with the two Valve Body Aligners as a guide. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5935 4. Note: The main control valve body screws will be tightened in later steps. Loosely install four M6 x 45 mm (1.8 inch) screws. 5. Note: The main control valve body screws will be tightened in later steps. Loosely install two M6 x 35 mm (1.4 inch) screws. 6. Remove the Valve Body Aligners. 7. Note: The main control valve body screws will be tightened in later steps. Loosely install the M6 x 30 mm (1.2 inch) screw. 8. Note: The main control valve body screws will be tightened in later steps. Loosely install the sixteen M6 x 40 mm (1.6 inch) main control valve body screws. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5936 9. Tighten the main control valve body screws in the sequence shown. 10. Install the manual control valve detent lever spring. 11. Install the low/reverse band servo piston and rod. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5937 12. Install the low/reverse band servo cover. 1. Install the low/reverse band servo cover and gasket. 2. Loosely install the low/reverse servo piston cover screws. 13. Tighten the servo cover screws in the sequence shown. 14. Connect the six solenoid electrical connectors. 1. Connect SSA, SSB, SSC, and SSD electrical connectors. 2. Connect the torque converter clutch (TCC) solenoid electrical connector. 3. Connect the electronic pressure control (EPC) solenoid electrical connector. 15. CAUTION: Excessive pressure may break the locating pins. Install the main control valve body wire harness. Align the retaining pins to the holes in the solenoid clamps and press in the main control valve body wire harness guide and protector. 16. Install the transmission fluid filter. 1. Install the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 5938 2. Install the transmission fluid filter screw. 17. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align the transmission fluid pan. 18. Tighten the transmission fluid pan screws. - Use a crisscross sequence to tighten the transmission fluid pan screws. 19. Position the servo heat shield over the servos and clip it to the pan rail. 20. Lower the vehicle. 21. Connect the battery ground cable. 22. Fill the transmission to the proper fluid level and check for proper transmission operation. - Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON V specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Service and Repair Wiring Harness: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect vehicle harness from transmission case (16 pin) connector. 4. Drain the transmission fluid. 5. Note: The main control assembly does not need to be removed. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 6. Remove main control valve body wire loom. - Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. 7. Disconnect the solenoid electrical connectors. 1. Disconnect the SSA, SSB, SSC, and the SSD electrical connectors. 2. Disconnect the torque converter clutch (TCC) solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Service and Repair > Page 5942 8. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. CAUTION: Shift solenoids may pop out of their bore. This may damage the solenoids. Remove the EPC and SSB solenoids. 1. Remove the solenoid clamp bolts. 2. Remove the solenoid clamp. 3. Remove the EPC and SSB solenoids. 9. CAUTION: Do not pry on the other wires or damage the connector case surface. Disconnect the turbine shaft speed (TSS) sensor electrical connector from the transmission case (16 pin) electrical connector. 1. Disconnect the TSS sensor electrical connector. 2. Remove from the TSS sensor wire locator. 10. CAUTION: Do not overstretch the retaining spring. Remove the transmission case (16 pin) electrical connector retaining spring. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Service and Repair > Page 5943 11. CAUTION: Do not damage the connector or harness. Remove the transmission case (16 pin) electrical connector. Compress the tabs on the transmission case (16 pin) electrical connector. - Push the transmission case (16 pin) electrical connector out of transmission case. Installation 1. Note: Make sure the tab is in the lock position. Note: Install new O-rings on the transmission case (16 pin) electrical connector. Install the transmission case (16 pin) electrical connector. Lubricate the transmission case (16 pin) electrical connector O-rings with petroleum jelly. 2. Press the transmission case (16 pin) electrical connector through the case until a click is heard. 3. CAUTION: Align the slot on the TSS sensor electrical connector with the slot in the 16 pin case connector. Install the TSS sensor wire. 1. Install TSS sensor wire into (16 pin) case connector. 2. Install TSS sensor wire into the locator. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Service and Repair > Page 5944 4. CAUTION: Do not overstretch the retaining spring. Install the transmission case (16 pin) electrical connector retaining spring. 5. Install the EPC and SSB solenoids. 6. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Service and Repair > Page 5945 7. Connect the SSA and SSC shift (SS) solenoid electrical connectors. 8. Connect the TCC, SSD, SSB, and EPC solenoid electrical connectors. 9. CAUTION: Excessive pressure may break the retaining pins. Install the wire harness guide and protector. Align the retaining pins to the holes in the solenoid clamps and gently press in the wire harness guide and protector. 10. Install the transmission fluid filter. 1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Service and Repair > Page 5946 11. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. - Loosely install the transmission fluid pan screws. 12. Tighten the transmission fluid pan screws. 13. Connect vehicle harness to transmission (16 pin) connector. Make sure lock is fully engaged. 14. Lower the vehicle. 15. Connect the battery ground cable. 16. Fill the transmission to the proper fluid level and check for proper transmission operation. - Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON V specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications Clutch Disc: Specifications O.S. Diameter (approx.) 10.2 in I.S. Diameter (approx.) 7.3 in Facing Area Sq. cm (sq. in) 508 (787) Compressed Thickness 0.307 in Lining Material Woven non-asbestos Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications > Page 5951 Clutch Disc: Service and Repair Special Tools Removal 1. Remove the transmission. 2. CAUTION: If the clutch disc and pressure plate are to be reinstalled, bolts must be removed evenly or permanent damage to the diaphragm spring win occur resulting in complete clutch release. Remove the clutch pressure plate and clutch disc. 1. If the parts are to be reused, mark the clutch pressure plate and flywheel. 2. Remove the bolts. 3. Remove the clutch pressure plate and clutch disc. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications > Page 5952 1. Note: Self-adjusting clutch pressure plate must be adjusted before installation. Compress the clutch diaphragm fingers. 1. Place the (A) flywheel and the (B) clutch pressure plate in a press. 2. Use a (C) suitable adapter and a (D) press to depress the (E) clutch diaphragm fingers until the adjusting ring moves freely. 2. Adjust the clutch pressure plate. - Rotate the (A) adjusting ring counterclockwise until the (B) tension springs are compressed. - Hold the (A) adjusting ring while releasing the pressure on the clutch fingers. 3. Position the (A) clutch disc on the (B) flywheel using the (C) Clutch Aligner. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications > Page 5953 4. Note: If reusing the clutch pressure plate and flywheel, align the marks made during removal. Position the clutch pressure plate on three dowels. 1. Align the clutch pressure plate and install the clutch pressure plate bolts. 2. Remove Clutch Aligner. 5. Install the transmission. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications Clutch Fluid Type DOT-3 Brake Fluid Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications Clutch Master Cylinder: Specifications Clutch Master Cylinder Reservoir Bolts 16 - 23 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications > Page 5961 Clutch Master Cylinder: Service and Repair Special Tool(s) Special Tool Clutch Master Cylinder/Reservoir Removal and Installation 1. Raise and support the vehicle. 2. Using the special tool, disconnect the hydraulic line from the clutch slave cylinder. 3. Lower the vehicle. 4. Disconnect the clutch pedal position (CPP) switch electrical connector. 5. Disconnect the clutch master cylinder rod from the clutch pedal arm. Remove and discard the clutch master cylinder push rod bushing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications > Page 5962 6. Remove the CPP switch. - Pinch the lock tabs and pull the clip forward. Rotate and snap the CPP switch from the clutch master cylinder rod. 7. Remove the reservoir. 8. Remove the three pushpins, four bolts, four screws and the inner fender splash shield. 9. Unclip the hydraulic line-to-frame retainer. 10. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, wash the surface with water immediately. Unlock and remove the clutch master cylinder assembly. Twist the clutch master cylinder clockwise 45 degrees to unlock it from the support bracket. - Remove the reservoir the hydraulic line and the clutch master cylinder as an assembly. Install a new clutch master cylinder push rod bushing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications > Page 5963 11. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, wash the surface with water immediately. To install, reverse the removal procedure. Bleed the clutch hydraulic system. Rotate the clutch master cylinder 45 degrees counterclockwise. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Specifications Clutch Slave Cylinder: Specifications Clutch Slave Cylinder Bolts 13 - 17 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Specifications > Page 5967 Clutch Slave Cylinder: Service and Repair Removal 1. Disconnect the clutch master cylinder hydraulic line from the clutch slave cylinder with (A) Clutch Coupling Tool. 2. Remove the transmission. 3. Note: Inspect the clutch housing for traces of fluid. If fluid is visible, replace the clutch slave cylinder. Remove the clutch slave cylinder. 1. Remove the bolts. 2. Remove the clutch slave cylinder. 4. CAUTION: The clutch release hub and bearing is prelubricated and should not be cleaned with solvent. The clutch release hub and bearing are replaced as an assembly. Do not disassemble for inspection or replacement. Remove the clutch release hub and bearing from the clutch slave cylinder. 1. Push the clutch release hub and bearing against the spring and move toward the base. 2. Remove the retainer ring and remove the clutch release hub and bearing and the spring. 5. Inspect the clutch slave cylinder for the following: - Weak spring. - Leaking fluid. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Specifications > Page 5968 1. Install the clutch release hub and bearing. - Lubricate the clutch release hub and bearing at sliding points with Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. 1. Position the (A) spring and the (B) clutch release hub and bearing onto the clutch slave cylinder. 2. Push the clutch release hub and bearing against the spring and install the retainer ring. 2. Install the clutch slave cylinder. 1. Position the clutch slave cylinder. 2. Install the bolts. 3. Install the transmission. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Service and Repair Hydraulic Hose: Service and Repair Removal 1. Raise and support the vehicle. 2. Disconnect the line from the plastic clip at the floor flange. 3. Uncouple the lower end of the clutch master cylinder hydraulic line from the clutch slave cylinder using (A) Clutch Coupling Tool. 4. Lower the vehicle. 5. Remove the clutch master cylinder and the hydraulic line assembly. 6. Remove and discard the roll pin holding the line to the clutch master cylinder. 7. Note: Check that the O-ring is still in the outlet port of the clutch master cylinder. If not, replace. Disconnect the line from the clutch master cylinder by applying a slight tug on the line. Installation 1. Insert the new line into the clutch master cylinder outlet port. 2. Install clutch master cylinder tube. 1. Position line and install roll pin. 2. Tug on clutch master cylinder tube. 3. Raise and support the vehicle. 4. Bleed the system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Service and Repair > Page 5972 5. Note: Check that the O-ring is in place on the line. Check the clutch slave cylinder port to be sure there is no O-ring. Insert the male coupling end into the female coupling of the clutch slave cylinder. Check that the connection is secure by applying a slight tug to the line. 6. Connect the line to the plastic clip on the floor flange. 7. Lower the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Service and Repair > Page 5973 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair Clutch Pedal Assembly: Service and Repair Removal 1. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface wash it immediately with water. Disconnect the clutch master cylinder push rod. 2. Remove the retainer ring. 3. Note: When the clutch pedal shaft is removed from the bracket, the brake pedal, brake and clutch pedal bushings, and spring washer become accessible. Remove the clutch pedal from the pedal support bracket. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair > Page 5977 1. Note: Before the installation of the clutch pedal shaft or clutch pedal, remove and inspect the brake and clutch pedal bushings. Clean and lubricate with a light film of SAE 30 engine oil X0-30-BSD or equivalent ESE-M2C153-E and replace the brake and clutch pedal bushing if excessive wear is evident. Install the clutch/brake pedal assembly. Install the clutch/brake pedal bushings and washers and the clutch pedal. - Install the clutch pedal shaft. 2. Install the retainer ring. 3. Install the clutch master cylinder push rod to pedal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair Pilot Bearing: Service and Repair Special Tools Removal 1. Note: Only replace the transmission input shaft pilot bearing if it is damaged. Remove the transmission input shaft pilot bearing using Impact Slide Hammer and Puller. 2. Inspect the transmission input shaft pilot bearing for: - misalignment and looseness in the flywheel. - needle rollers for scoring, worn or broken needle rollers, inadequate grease or discoloration. - seal leakage. 3. CAUTION: To prevent damage, do not use cleaners with a petroleum base and do not immerse the clutch pressure plate in solvent. Clean the clutch pressure plate using a suitable commercial alcohol-based solvent so surface is free from oil film. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair > Page 5984 1. Note: The transmission input shaft pilot bearing can only be installed with the seal facing the transmission. The transmission input shaft pilot bearing is pregreased and does not require additional lubrication. A new transmission input shaft pilot bearing must be installed whenever it is removed. Install the (A) transmission input shaft pilot bearing using (B) Pilot Bearing Replacer. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications Pressure Plate: Specifications Clutch Pressure Plate Bolts 17 - 23 ft.lb Total Plate Pressure 2248-315 lbf Diaphragm Spring Belleville Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 5988 Pressure Plate: Service and Repair Special Tools Removal 1. Remove the transmission. 2. CAUTION: If the clutch disc and pressure plate are to be reinstalled, bolts must be removed evenly or permanent damage to the diaphragm spring win occur resulting in complete clutch release. Remove the clutch pressure plate and clutch disc. 1. If the parts are to be reused, mark the clutch pressure plate and flywheel. 2. Remove the bolts. 3. Remove the clutch pressure plate and clutch disc. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 5989 1. Note: Self-adjusting clutch pressure plate must be adjusted before installation. Compress the clutch diaphragm fingers. 1. Place the (A) flywheel and the (B) clutch pressure plate in a press. 2. Use a (C) suitable adapter and a (D) press to depress the (E) clutch diaphragm fingers until the adjusting ring moves freely. 2. Adjust the clutch pressure plate. - Rotate the (A) adjusting ring counterclockwise until the (B) tension springs are compressed. - Hold the (A) adjusting ring while releasing the pressure on the clutch fingers. 3. Position the (A) clutch disc on the (B) flywheel using the (C) Clutch Aligner. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 5990 4. Note: If reusing the clutch pressure plate and flywheel, align the marks made during removal. Position the clutch pressure plate on three dowels. 1. Align the clutch pressure plate and install the clutch pressure plate bolts. 2. Remove Clutch Aligner. 5. Install the transmission. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications Differential Case: Specifications Maximum differential case runout ................................................................................................................................................ 0.076 mm (0.003 inch) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly Differential Case: Service and Repair Disassembly and Assembly Differential Case and Ring Gear-Conventional Special Tools Disassembly 1. Remove the differential case. 2. Remove the 10 ring gear bolts. 3. CAUTION: Care should be taken not to damage the bolt hole threads. Insert a punch in the bolt holes and drive the ring gear off. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5997 4. Note: The speed sensor ring cannot be reused once removed. Remove the speed sensor ring if required. 5. If required, use the special tools to remove the differential bearings. 6. Remove the differential pinion shaft lock bolt. 7. Remove the differential pinion shaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5998 8. Rotate and remove the differential pinion gears and the differential pinion thrust washers. 9. Remove the differential side gears and the differential side gear thrust washers. Assembly 1. Lubricate the differential side gear thrust washers and the differential side gear journals. - For vehicles with 5.0L engines, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B meeting Ford specification WSL-M2C192-A. - For vehicles with 4.0L engines, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL meeting Ford specification WSP-M2C197-A. - Position thee differential side gear thrust washers on the differential side gears. 2. Position the differential side gears. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 5999 3. Lubricate the differential pinion thrust washers and the differential pinion gears and assemble. - For vehicles with 5.0L engines, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B meeting Ford specification WSL-M2C192-A. - For vehicles with 4.0L engines, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL meeting Ford specification WSP-M2C197-A. 4. Engage the differential pinion gears opposite the differential side gears. 5. Rotate the differential pinion gears to align with the differential pinion shaft bore. 6. Insert the differential pinion shaft. - Align the hole in the differential pinion shaft with the hole in the differential case. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 6000 7. CAUTION: If a new pinion shaft lock bolt is unavailable, coat the threads with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specifications WSK-M2G351-A5 prior to installation. Install a new differential pinion shaft lock bolt and tighten finger-tight. 8. Using the special tool, install the new differential bearings on the differential case. 9. Press the new anti-lock speed sensor ring and the ring gear on the differential case. 10. Install the ring gear bolts. - Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to ring gear bolts. 11. Install the differential case. Differential Case and Ring Gear-Traction-LOK Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 6001 Special Tools Special Tools Disassembly 1. Remove the differential case. 2. Remove the 10 bolts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 6002 3. CAUTION: Do not damage the bolt hole threads. Insert a punch in the bolt holes, and drive the ring gear off. 4. CAUTION: Do not reuse the anti-lock speed sensor ring after removing it. If necessary, remove the anti-lock speed sensor ring and discard it. 5. Using the special tools, remove the differential bearings. 6. Remove the differential pinion shaft lock bolt, and remove the differential pinion shaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 6003 7. WARNING: Due to the spring tension, take care when removing the differential clutch spring. Remove the differential clutch spring. 8. Remove the differential gears and washers. 1. Remove the differential pinion gears. 2. Remove the differential side gears. 3. Remove the differential pinion thrust washers Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 6004 9. CAUTION: Keep the differential clutch packs in order. Do not mix them. Be sure to reassemble them in the same sequence. Remove and tag the differential clutch packs, shims and differential side gears "right" and left". 10. CAUTION: Do not use acids or solvents to clean the differential clutch packs. Wipe the components with a clean, lint-free cloth only. Clean and inspect the differential clutch packs for wear and damage. Install new parts as necessary. 11. Clean and inspect the remaining differential case components for wear and damage. Install new components as necessary. Assembly 1. CAUTION: Use 118 ml. (4 oz.) of Ford Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A in the axle. Prelubricate each steel clutch plate and soak all of the friction plates in Ford Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A for at least 15 minutes. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 6005 2. CAUTION: Do not mix the left and right side differential clutch packs and shims. Assemble the left and right differential clutch packs (without the shims) and differential side gears. 3. CAUTION: Use the correct mandrel with the Differential Clutch Gauge. Place the special tool in a vise. 4. Install the differential clutch pack and differential side gear (without the shim) on the special tool. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 6006 5. Position the special tool hand-tight on top of the differential clutch pack. 6. Install the special tool over the disc and differential clutch pack. 7. Install the nut. 8. Note: Clutch Pack Kit FSAZ-4947-BA is available to rebuild the 8.8-inch ring gear Traction-Lok differential. Using the special tool, determine the thickness of the new clutch shim. Insert the thickest blade that will enter between the tool and the differential clutch pack. Selective Shims 9. Remove the special tool from the clutch pack and side gear assembly. 10. Install the shims on the clutch pack and side gear assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 6007 11. Install the differential side gear assemblies in the differential case. 12. Install the differential pinion gears with the differential pinion thrust washers in the differential case. 13. Using a soft-faced hammer, install the differential clutch spring. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 6008 14. Install the differential pinion shaft, and install a new differential pinion shaft lock bolt finger-tight. 15. Using the special tool, install the differential bearings. 16. Install the anti-lock speed sensor ring by aligning the tab with the slot. - Start two bolts through the differential case and into the ring gear to make sure the ring gear bolt holes align with the differential case bolt holes. 17. Press the new anti-lock speed sensor ring and the ring gear on the differential case. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 6009 18. Install the bolts. - Apply Stud and Bearing Mount EOAZI9554-BA or equivalent meeting Ford specification WSK-M2G349-AI to the bolt threads. 19. Install the differential case. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 6010 Differential Case: Service and Repair Removal and Installation Special Tools Special Tools Special Service Tool(s) Removal 1. Remove the axle shafts. 2. Wipe the lubricant from the internal working parts and visually inspect the parts for wear and damage. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 6011 3. Rotate the differential case to see if there is any roughness which would indicate damaged bearings or gears. 4. Note: There is a space between the anti-lock speed sensor ring and the ring gear for measuring ring gear backface runout. Position the special tool and check the ring gear backlash and ring gear backface runout. 5. CAUTION: Mark the position of the bearing caps, as the arrows may not be visible. The bearing caps must be installed in their identical locations and positions. Loosen the differential case. 1. Remove the four bearing cap bolts. 2. Remove the two bearing caps. 6. WARNING: Be careful not to allow the differential case to fall. CAUTION: Place a wood block between the pry bar and the rear axle housing to protect the machined surface from damage. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 6012 Use the pry bar and the wood block to remove the differential case from the rear axle housing. 7. Remove the 10 ring gear bolts. 8. CAUTION: Care should be taken not to damage the ring bolt hole threads. CAUTION: The anti-lock speed sensor ring cannot be reused once removed. Insert a punch in the bolt holes and drive off the ring gear and, if necessary, the anti-lock speed sensor ring. 9. Install the differential case. - Position the differential case assembly, including the bearing cups and shims, in the rear axle housing. Install the differential bearing caps and the differential bearing cap bolts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 6013 10. Position the special tool. 1. Rotate the differential case to make sure the differential bearings are correctly seated. 2. Position the special tool. 11. Note: If runout is less than the specification, install a new ring gear and pinion. If runout exceeds the specification, the ring gear is true and the concern is due to either a damaged differential case or differential bearings. Inspect the differential bearings. If the differential bearings are not damaged, install a new differential case and differential bearings. Measure the differential case runout without the ring gear. 12. Remove the differential case from the rear axle housing and remove the differential bearings using the special tools. 13. Use the special tool to install the new differential bearings on the differential case. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 6014 14. Install the differential case. Position the differential case assembly, including the bearing cups and shims in the rear axle housing. Tighten bearing caps to specifications. 15. Measure the differential case runout without the ring gear, and check the case runout again with the new differential bearings. - If the runout is now less than the specification shown, use the new differential bearings for assembly. - If the runout is still excessive, the differential case is damaged and a new differential case must be installed. Installation All vehicles 1. Press a new anti-lock speed sensor ring, if removed, and the ring gear on the differential case. - Align the notch on the differential case flange with the notch on the anti-lock speed sensor ring. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 6015 2. Install the ring gear bolts. - Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-AI to ring gear bolts. 3. With pinion depth set and pinion installed, place the differential case in the rear axle housing. 4. Install a shim on the left side. 5. CAUTION: Mark the position of the bearing caps as the arrows may not be visible. The bearing caps must be installed in their identical locations and positions. Note: Apply pressure toward the left side to make sure the left bearing cap is seated. Install the left bearing cap and loosely install the bearing cap bolts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 6016 6. Install progressively larger shims on the right side until the largest shim selected can be assembled by hand. 7. Install the right side bearing cap and tighten the left side and right side bolts to specification. 8. Rotate the differential case to make sure it rotates freely. Measuring backlash 9. Use the special tool to measure the ring gear backlash. - If the backlash is within specification, go to Backlash within specification in this procedure. - If a zero backlash condition occurs, go to Zero backlash in this procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 6017 - If the backlash is not within specification, go to Backlash not within specification in this procedure. Zero backlash 10. If a zero backlash condition occurs, add 0.51 mm (0.020 inch) to the RH side and subtract 0.51 mm (0.020 inch) from the LH side to allow backlash indication. Cheek the backlash. Repeat Measuring backlash in this procedure. Backlash not within specification 11. To increase or decrease the backlash, remove the bearing caps and install a thicker shim or a thinner shim as shown. - If the backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness of the other differential bearing shim by the same amount. 12. Rotate the differential several times to make sure the differential bearings are correctly seated. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 6018 13. Using the special tool, recheck the backlash. - If the backlash is within specification, go to Backlash within specification in this procedure. If the backlash is not within specification, repeat measuring backlash in this procedure. Backlash within specification 14. Remove the bearing caps and bolts. - To establish differential bearing preload, increase both left and right shim sizes by the specification shown in the illustration. - Using the special tool, make sure that the differential bearing shims are fully seated and the assembly turns freely. 15. Install the bearing caps and bearing cap bolts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Disassembly and Assembly > Page 6019 16. Using the special tool, recheck the backlash. 17. Install the axle shafts. 18. Install the differential housing cover and refill the rear axle with specified lubricant. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications Differential Cover: Specifications Torque Specifications Differential housing cover bolts ........................................................................................................................................................... 45 Nm (33 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Page 6023 Differential Cover: Service and Repair Removal 1. Raise and support the vehicle. 2. Remove the differential housing cover. 1. Loosen the bolts and drain the lubricant from the rear axle housing. 2. Remove the bolts. 3. Remove the differential housing cover. Installation 1. CAUTION: Make sure the machined surface on the rear axle housing and the differential housing cover are clean and free of oil before applying the new silicone sealant. To prevent contamination, cover the inside of the rear axle prior to cleaning the machined surface. Clean the rear axle housing and the differential housing cover gasket mating surfaces. 2. CAUTION: Install the differential housing cover within 15 minutes of applying the silicone, or it will be necessary to remove and reapply new sealant. Apply a new continuous bead of sealant to the differential housing cover. Use Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specifications ESB-M4G92-A. 3. Note: If possible, allow one hour before filling the axle with lubricant to make sure the silicone sealant has cured. Install the differential housing cover. 1. Install the differential housing cover. 2. Install the bolts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Page 6024 4. CAUTION: For Traction-Lok axles, first fill the rear axle with 118 ml. (4 oz.) of Ford Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A. Note: In-vehicle repair refill capacities are determined by filling the rear axle to the level shown. Fill the rear axle. For vehicles with 4.0L SOHC and 4.0L EI with Traction-Lok rear axles and 5.0L, use 2.4 liters (5.5 pints) of SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-1 9580-B or equivalent meeting Ford specification WSL-M2C192-A, and install the filler plug - For vehicles with 4.0L SOHC and 4.0L EI with conventional rear axles, use 2.4 liters (5.5 pints) of SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. 5. Lower the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fill Plug, Differential > Component Information > Specifications > Solid Rear Axle Fill Plug: Specifications Solid Rear Axle Filler plug ............................................................................................................................................. .................................................... 30 Nm (22 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fill Plug, Differential > Component Information > Specifications > Solid Rear Axle > Page 6029 Fill Plug: Specifications Independent Rear Axle Filler plug ............................................................................................................................................. .................................................... 34 Nm (25 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Refill ..................................................................................................................................................... ............................................................. 5.5-5.8 pints Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 6034 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A for 4.0L SOHC and 4.0L EI with a conventional differential. Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A for 4.0L SOHC and 4.0L EI with a limited slip differential and 5.0L. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications > Solid Rear Axle Pinion Bearing: Specifications Pinion bearing preload (used pinion bearings) 8 - 14 in.lb Pinion bearing preload (new pinion bearings) 16 - 29 in.lb Differential bearing cap bol 77 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications > Solid Rear Axle > Page 6039 Pinion Bearing: Specifications Independent Rear Axle Driveshaft to Pinion Flange Bolt .......................................................................................................... ..................................................... 112 Nm. (83 lb-ft) Differential Pinion Shaft Lock Bolt ............................................................................................................................................................ 30 Nm. (22 lb-ft) * Pinion Bearing Preload (Used Bearings) ..................................................................................................................................... 0.9-1.16 Nm (8-14 lb-in) New Pinion Bearing ............................................................................................................................. .......................................... 1.8-3.2 Nm. (16-29 lb-in) * With Pinion Flange Yoke Seal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Solid Rear Axle Pinion Flange: Service and Repair Solid Rear Axle Special Tools Removal 1. CAUTION: Do not allow the calipers to hang from the brake hoses. Note: Remove the rear wheels and the rear disc brake calipers to prevent brake drag during the drive pinion bearing preload adjustment. Remove the rear disc brake calipers. 2. Index-mark the driveshaft flange and pinion flange to maintain initial balance during installation. 3. Remove the four bolts and disconnect the d rive shaft. - Position the driveshaft aside. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Solid Rear Axle > Page 6044 4. Install a Nm (inch-pound) torque wrench on the pinion nut, and record the torque necessary to maintain rotation of the pinion through several revolutions. 5. CAUTION: After removing the pinion nut, discard it. Use a new nut for installation. Use the special tool to hold the pinion flange while removing the pinion nut. 6. Index-mark the pinion flange and the drive pinion stem to maintain initial balance during installation. 7. Using the special tool, remove the pinion flange. Installation 1. Lubricate the pinion flange splines. - For vehicles with 4.0L SOHC and 4.0L EI with Traction-Lok(r) differentials and 5.0L, use Motorcraft Synthetic 75W140 Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - For vehicles with 4.0L SOHC and 4.0L EI with conventional differentials, use Thermally Stable Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Solid Rear Axle > Page 6045 2. Note: Disregard the scribe marks if installing a new pinion flange. Align the pinion flange with the drive pinion shaft. 3. Using the special tools, install the pinion flange. 4. CAUTION: Do not under any circumstance loosen the pinion nut to reduce preload. If it is necessary to reduce preload, install a new collapsible spacer and pinion nut. CAUTION: Remove the special tool when taking preload readings with the Nm (inch-pound) torque wrench. Use the special tool to hold the pinion flange while tightening the pinion nut. Rotate the pinion occasionally to make sure the pinion bearings seat correctly. Take frequent pinion bearing torque preload readings by rotating the pinion with a Nm (inch-pound) torque wrench. - If the preload recorded prior to disassembly is lower than the specification for used bearings, then tighten the pinion nut to specification. If the preload recorded prior to disassembly is higher than the specification for used bearings, then tighten the pinion nut to the original reading as recorded. - Refer to the torque specification for used pinion bearings. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Solid Rear Axle > Page 6046 5. CAUTION: Be sure to align the index-marks. Connect the driveshaft. 6. Install the rear disc brake calipers. 7. Install the rear wheel and tire assemblies. 8. Refer to the specified axle lubricant type and fill capacity. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Solid Rear Axle > Page 6047 Pinion Flange: Service and Repair Independent Rear Suspension Drive Pinion Flange and Drive Pinion Seal Special Tools Material Premium Long Life Grease XG-1-C .......................................................................................................................................................... ESA-M1C75-B Threadlock and Sealer EOAZ-19554-AA .............................................................................................................................. WSK-M2G351-A5 (type II) Silicone Brake Caliper Grease & Dielectric Compound ........................................................................................................................... ESE-M1C171-A Removal 1. Position vehicle on hoist. 2. Remove the rear wheel and tire assemblies. 3. CAUTION: Remove the rear brake calipers to prevent drag during the drive pinion bearing preload adjustment. CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The guide pins are meant to be sealed for life and are not repairable. Use brake caliper grease for re-lubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Solid Rear Axle > Page 6048 contamination and accelerated corrosion and wear of the caliper slide pin mechanism. CAUTION: Do not allow the calipers to hang from the brake hoses. Support the caliper assembly with a length of mechanic's wire. Remove the rear disc brake caliper assembly. 1. Remove the caliper bolts. 2. Using a disc brake pad spreader, spread the disc brake pads to allow caliper removal. 4. CAUTION: Index-mark the driveshaft flange and rear axle pinion flange for correct alignment during installation. Remove the four bolts. 5. CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft flange from the pinion flange. Pry only in the area shown, with a suitable tool, to disconnect the driveshaft flange from the pinion flange. Using a suitable tool as shown, disconnect the driveshaft flange from the rear axle flange, and position and secure the driveshaft aside. 6 Install a Nm (inch-pound) torque wrench on the nut and record the torque necessary to maintain rotation of the pinion through several revolutions. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Solid Rear Axle > Page 6049 7. CAUTION: Discard the nut after removing it. Install a new nut during installation. Use the special tool to hold the pinion flange while removing the nut. 8. Index-mark the pinion flange and the drive pinion stem for correct alignment during installation. 9. Using the special tool, remove the pinion flange. 10. Using the special tools, remove and discard the rear axle drive pinion seal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Solid Rear Axle > Page 6050 Installation 1. Coat the new rear axle drive pinion seal lips with long life grease. 2. CAUTION: Installation without the correct tool can result in early seal failure. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the seal and install a new seal. Using the special tool, install the rear axle drive pinion seal. 3. Inspect the rear axle pinion flange seal journal for rust, nicks and scratches prior to installing the flange. Polish the seal journal with fine crocus cloth, if necessary. 4. NOTE: Disregard the index marks if installing a new pinion flange. Position the pinion flange. 5. Using the special tool, install the pinion flange. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Solid Rear Axle > Page 6051 6. CAUTION: Do not, under any circumstance, loosen the nut to reduce preload. If it is necessary to reduce preload, install a new collapsible spacer and nut. CAUTION: Remove the special tool while taking preload readings with the Nm (inch- pound) torque wrench. Use the special tool to hold the pinion flange while tightening the nut. - Rotate the pinion occasionally to make sure the differential pinion bearings seat correctly. Take frequent differential pinion bearing preload readings by rotating the pinion with a Nm (inch- pound) torque wrench. - If the preload recorded prior to disassembly is lower than the specification for used bearings, tighten the nut to specification. If the preload recorded prior to disassembly is higher than the specification for used bearings, tighten the nut to the original reading as recorded. - Refer to torque specifications for used pinion bearings in the Specifications portion of this section. 7. NOTE: Align the index marks. Install the four driveshaft flange to pinion flange bolts. 8. CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. To make sure that the yoke seats squarely on the flange, tighten the bolts evenly in a cross pattern as shown. CAUTION: If new bolts to retain the driveshaft to the axle flange are not available, coat the threads of the original bolts with threadlock and sealer. Tighten to specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Solid Rear Axle > Page 6052 9. CAUTION: To prevent interference with the rear disc brake caliper operation, install only the correct caliper bolt. NOTE: Make sure the stainless steel shoe slippers are correctly positioned. Install new slippers if worn or damaged. NOTE: Use the disc brake pad spreader to spread pads for reassembly. Install the rear disc brake caliper. 10. Install the rear wheel and tire assemblies. 11. Lower the vehicle. 12. Apply the brake pedal to make sure of rear disc brake caliper piston position. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Solid Rear Axle Pinion Gear: Service and Repair Solid Rear Axle Special Tools Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Solid Rear Axle > Page 6057 Special Tools Special Tools Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Solid Rear Axle > Page 6058 Special Tools Removal 1. Remove the differential case. 2. CAUTION: Record the torque necessary to maintain rotation of the pinion through several revolutions prior to removing the pinion flange (48S1). Remove the pinion flange. 3. Remove the rear axle drive pinion seal. 4. Remove the rear axle drive pinion shaft oil slinger. 5. Using the special tool and a soft-faced hammer, drive the pinion assembly out of the outer pinion bearing, and remove the pinion through the rear of the housing. 6. Remove the outer pinion bearing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Solid Rear Axle > Page 6059 7. Remove and discard the collapsible spacer. 8. Using the special tool and a suitable press, remove the inner pinion bearing. 9. Note: Do not remove the pinion bearing cups from the axle housing unless the cups are damaged. To remove the bearing cups, tap alternately (with a brass drift of suitable length) on opposite sides of the cup to prevent the cup from cocking in the casting. Installation Using 205-024 1. Position the special tools and the inner and outer bearing cups in their respective axle housing bores. 1. After placing the inner and outer bearing cups in their bores, place the special tool (inner) on the inner pinion bearing cup. 2. Place the special tool (outer) on the outer pinion bearing cup. 3. Install the special tool. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Solid Rear Axle > Page 6060 2. Tighten the special tool to scat the pinion bearing cups in their bores. Using 205-153 and 205-DOS5 3. Using the special tools, drive the outer pinion bearing cup into the axle housing. 4. Using the special tools, drive the inner pinion bearing cup into the axle housing. Setting pinion depth 5. CAUTION: Always install new pinion bearings when installing new bearing cups. Note: If the feeler gauge can fit between a cup and the bottom of its bore at any point around the cup, remove and reseat the cup. Check that the cups have seated correctly in their bores. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Solid Rear Axle > Page 6061 6. Note: Apply only a light oil film on the pinion bearings before assembling the tools. Assemble and position the special tools and pinion bearings in the axle housing. 1. Position the Screw. 2. Position the Aligning Adapter. 3. Position the inner pinion bearing. 4. Position the Gauge Disc. 5. Position the Gauge Block. 6. Position the outer pinion bearing. 7. Thread on the Handle. 7. Note: This step simulates pinion bearing preload. Using a Nm (inch-pound) torque wrench, tighten the Handle to the specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Solid Rear Axle > Page 6062 8. Note: Offset the Gauge Block to obtain an accurate reading. Rotate the Gauge Block several half-lures to make sure of correct seating of the pinion bearings and position the Gauge Block. 9. Install the special tool. 1. Position the special tool. 2. Install the bearing caps. 3. Install the four bolts. 10. Note: Use only flat, clean drive pinion bearing adjustment shims. Note: Selection of too thick a pinion shim results in a deep tooth contact at final assembly of integral rear axle assemblies. Do not attempt to force the pinion shim between the Gauge Block and the Gauge Tube. A slight drag indicates correct shim selection. Use a drive pinion bearing adjustment shim as a gauge for shim selection. Check the pinion bearing adjustment shim thickness between the Gauge Block and the Gauge Tube. - After determining the correct shim thickness, remove the special tools. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Solid Rear Axle > Page 6063 11. Using the special tool and a suitable press, seat the pinion bearing firmly against the pinion gear. 12. Place a new collapsible spacer on the pinion shaft against the pinion stem shoulder. 13. Install the outer pinion bearing. 14. Install the rear axle drive pinion shaft oil slinger. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Solid Rear Axle > Page 6064 15. CAUTION: Installation without the correct tool can result in early seal failure. Note: Coat the lips of the rear axle drive pinion seal with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Place the rear axle drive pinion seal on the special tool. 16. CAUTION: If the rear axle drive pinion seal becomes cocked during installation, remove it and install a new one. Place the special tool and seal in the pinion seal bore and drive the rear axle drive pinion seal into place. 17. Install the pinion assembly (pinion, shims, inner pinion bearing, and collapsible spacer) into the rear axle housing bore. 18. Lubricate the pinion flange splines. - Vehicles with 4.0L SOHC and 4.0L EI with a conventional differential, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. - Vehicles with 4.0L SOHC and 4.0L EI with Limited Slip differential and 5.0L, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 19. Note: Disregard the alignment marks if installing a new pinion flange. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Solid Rear Axle > Page 6065 Align the pinion flange with the drive pinion shaft. 20. Using the special tools, install the pinion flange. 21. CAUTION: Do not under any circumstance loosen the pinion nut to reduce preload. If it is necessary to reduce preload, install a new collapsible spacer and pinion nut. CAUTION: Remove the special tool when taking preload readings with the Nm (inch-pound) torque wrench. Use the special tool to hold the pinion flange while tightening the pinion nut. Rotate the pinion occasionally to make sure the cone and roller bearings are seating correctly. - Install a Nm (inch-pound) torque wrench on the pinion nut. - Rotating the pinion through several revolutions, take frequent cone and roller bearing torque preload readings until the original recorded preload reading is obtained. - If the original recorded preload is lower than specifications, tighten to the appropriate specifications for used bearings. If the preload is higher than specification, tighten the nut to the original reading as recorded. Refer to the torque specification for new pinion bearings. 22. Install differential case and the remaining components. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Solid Rear Axle > Page 6066 Pinion Gear: Service and Repair Independent Rear Suspension Drive Pinion Flange and Drive Pinion Seal Special Tools Material Premium Long Life Grease XG-1-C .......................................................................................................................................................... ESA-M1C75-B Threadlock and Sealer EOAZ-19554-AA .............................................................................................................................. WSK-M2G351-A5 (type II) Silicone Brake Caliper Grease & Dielectric Compound ........................................................................................................................... ESE-M1C171-A Removal 1. Position vehicle on hoist. 2. Remove the rear wheel and tire assemblies. 3. CAUTION: Remove the rear brake calipers to prevent drag during the drive pinion bearing preload adjustment. CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The guide pins are meant to be sealed for life and are not repairable. Use brake caliper grease for re-lubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Solid Rear Axle > Page 6067 contamination and accelerated corrosion and wear of the caliper slide pin mechanism. CAUTION: Do not allow the calipers to hang from the brake hoses. Support the caliper assembly with a length of mechanic's wire. Remove the rear disc brake caliper assembly. 1. Remove the caliper bolts. 2. Using a disc brake pad spreader, spread the disc brake pads to allow caliper removal. 4. CAUTION: Index-mark the driveshaft flange and rear axle pinion flange for correct alignment during installation. Remove the four bolts. 5. CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft flange from the pinion flange. Pry only in the area shown, with a suitable tool, to disconnect the driveshaft flange from the pinion flange. Using a suitable tool as shown, disconnect the driveshaft flange from the rear axle flange, and position and secure the driveshaft aside. 6 Install a Nm (inch-pound) torque wrench on the nut and record the torque necessary to maintain rotation of the pinion through several revolutions. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Solid Rear Axle > Page 6068 7. CAUTION: Discard the nut after removing it. Install a new nut during installation. Use the special tool to hold the pinion flange while removing the nut. 8. Index-mark the pinion flange and the drive pinion stem for correct alignment during installation. 9. Using the special tool, remove the pinion flange. 10. Using the special tools, remove and discard the rear axle drive pinion seal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Solid Rear Axle > Page 6069 Installation 1. Coat the new rear axle drive pinion seal lips with long life grease. 2. CAUTION: Installation without the correct tool can result in early seal failure. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the seal and install a new seal. Using the special tool, install the rear axle drive pinion seal. 3. Inspect the rear axle pinion flange seal journal for rust, nicks and scratches prior to installing the flange. Polish the seal journal with fine crocus cloth, if necessary. 4. NOTE: Disregard the index marks if installing a new pinion flange. Position the pinion flange. 5. Using the special tool, install the pinion flange. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Solid Rear Axle > Page 6070 6. CAUTION: Do not, under any circumstance, loosen the nut to reduce preload. If it is necessary to reduce preload, install a new collapsible spacer and nut. CAUTION: Remove the special tool while taking preload readings with the Nm (inch- pound) torque wrench. Use the special tool to hold the pinion flange while tightening the nut. - Rotate the pinion occasionally to make sure the differential pinion bearings seat correctly. Take frequent differential pinion bearing preload readings by rotating the pinion with a Nm (inch- pound) torque wrench. - If the preload recorded prior to disassembly is lower than the specification for used bearings, tighten the nut to specification. If the preload recorded prior to disassembly is higher than the specification for used bearings, tighten the nut to the original reading as recorded. - Refer to torque specifications for used pinion bearings in the Specifications portion of this section. 7. NOTE: Align the index marks. Install the four driveshaft flange to pinion flange bolts. 8. CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. To make sure that the yoke seats squarely on the flange, tighten the bolts evenly in a cross pattern as shown. CAUTION: If new bolts to retain the driveshaft to the axle flange are not available, coat the threads of the original bolts with threadlock and sealer. Tighten to specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Solid Rear Axle > Page 6071 9. CAUTION: To prevent interference with the rear disc brake caliper operation, install only the correct caliper bolt. NOTE: Make sure the stainless steel shoe slippers are correctly positioned. Install new slippers if worn or damaged. NOTE: Use the disc brake pad spreader to spread pads for reassembly. Install the rear disc brake caliper. 10. Install the rear wheel and tire assemblies. 11. Lower the vehicle. 12. Apply the brake pedal to make sure of rear disc brake caliper piston position. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications > Solid Rear Axle Ring Gear: Specifications Solid Rear Axle Clearance, Tolerance and Adjustments Maximum ring gear backface runout ............................................................................................................................................ 0.102 mm (0.004 inch) Backlash between ring gear and pinion teeth .............................................................................................................................................................. .................................. 0.203 mm (0.008 inch) ...................................................................................... .......................................................................................................... 0.381 mm (0.015 inch) .............. .............................................................................................................................................................. .................... 0.305 mm (0.012 inch) .................................................................................................... ............................................................................ 0.381 mm (0.015 inch) preferred Maximum ring gear backlash variation between teeth .................................................................................................................. 0.102 mm (0.004 inch) Torque Specifications Ring gear bolts .................................................................................................................................... .................................... 95-115 Nm (70-85 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications > Solid Rear Axle > Page 6076 Ring Gear: Specifications Independent Rear Suspension Clearance, Tolerance and Adjustments Backlash between differential ring gear and pinion teeth .............................................................................................................................................................. ........ 0.208mm (0.008in) - 0.305mm (0.012in) Preferred backlash .............................................................................................................................. .................................................. 0.254mm (0.010in) Torque Specifications Ring gear bolts* ................................................................................................................................... .............................................. 105 Nm (77 ft. lbs.) * Use stud and bearing mount E)AZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Independent Rear Suspension Ring Gear: Service and Repair Independent Rear Suspension Differential Ring Gear Backlash Special Tools Material 1. Position the vehicle on a hoist. 2. Remove the drain plug from the differential housing cover and drain the differential fluid. 3. Remove the differential cover bolt from the 6 o'clock position. 4. Mount the special tool in the 6 o'clock position of the differential cover, using the differential cover bolt. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Independent Rear Suspension > Page 6079 5. Using the special tools, mount a suitable backlash dial indicator allowing the indicator tip to contact the drive side of the ring gear tooth through the drain plug hole. 6. Rotate the left halfshaft inner CV joint to move the ring gear fore and aft to measure the backlash between the ring gear teeth and the pinion teeth. Record the backlash. 7. Remove the dial indicator and rotate the driveshaft to turn the differential ring gear. Position the dial indicator and record the backlash in four places around the ring gear. 8. Proceed as follows: - If the backlash is outside the range of 0.254 mm-0.305 mm (0.010-0.012 in), remove the differential for further investigation. - If the backlash is within specification, remove the tools, install the drain plug and refill the axle to specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Independent Rear Suspension > Page 6080 9. Lower the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Solid Rear Axle Seals and Gaskets: Service and Repair Solid Rear Axle Special Tools Removal 1. Remove the pinion flange. 2. Force up on the metal flange of the rear axle drive pinion seal. Install gripping pliers and strike with a hammer until the rear axle drive pinion seal is removed. Installation 1. Lubricate the new rear drive pinion seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1 C75-B. 2. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the rear axle drive pinion seal and install a new seal. Using the special tool, install the rear axle drive pinion seal. 3. Install the pinion flange. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Solid Rear Axle > Page 6085 Seals and Gaskets: Service and Repair Independent Rear Suspension Drive Pinion Flange and Drive Pinion Seal Special Tools Material Premium Long Life Grease XG-1-C .......................................................................................................................................................... ESA-M1C75-B Threadlock and Sealer EOAZ-19554-AA .............................................................................................................................. WSK-M2G351-A5 (type II) Silicone Brake Caliper Grease & Dielectric Compound ........................................................................................................................... ESE-M1C171-A Removal 1. Position vehicle on hoist. 2. Remove the rear wheel and tire assemblies. 3. CAUTION: Remove the rear brake calipers to prevent drag during the drive pinion bearing preload adjustment. CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The guide pins are meant to be sealed for life and are not repairable. Use brake caliper grease for re-lubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Solid Rear Axle > Page 6086 contamination and accelerated corrosion and wear of the caliper slide pin mechanism. CAUTION: Do not allow the calipers to hang from the brake hoses. Support the caliper assembly with a length of mechanic's wire. Remove the rear disc brake caliper assembly. 1. Remove the caliper bolts. 2. Using a disc brake pad spreader, spread the disc brake pads to allow caliper removal. 4. CAUTION: Index-mark the driveshaft flange and rear axle pinion flange for correct alignment during installation. Remove the four bolts. 5. CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft flange from the pinion flange. Pry only in the area shown, with a suitable tool, to disconnect the driveshaft flange from the pinion flange. Using a suitable tool as shown, disconnect the driveshaft flange from the rear axle flange, and position and secure the driveshaft aside. 6 Install a Nm (inch-pound) torque wrench on the nut and record the torque necessary to maintain rotation of the pinion through several revolutions. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Solid Rear Axle > Page 6087 7. CAUTION: Discard the nut after removing it. Install a new nut during installation. Use the special tool to hold the pinion flange while removing the nut. 8. Index-mark the pinion flange and the drive pinion stem for correct alignment during installation. 9. Using the special tool, remove the pinion flange. 10. Using the special tools, remove and discard the rear axle drive pinion seal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Solid Rear Axle > Page 6088 Installation 1. Coat the new rear axle drive pinion seal lips with long life grease. 2. CAUTION: Installation without the correct tool can result in early seal failure. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the seal and install a new seal. Using the special tool, install the rear axle drive pinion seal. 3. Inspect the rear axle pinion flange seal journal for rust, nicks and scratches prior to installing the flange. Polish the seal journal with fine crocus cloth, if necessary. 4. NOTE: Disregard the index marks if installing a new pinion flange. Position the pinion flange. 5. Using the special tool, install the pinion flange. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Solid Rear Axle > Page 6089 6. CAUTION: Do not, under any circumstance, loosen the nut to reduce preload. If it is necessary to reduce preload, install a new collapsible spacer and nut. CAUTION: Remove the special tool while taking preload readings with the Nm (inch- pound) torque wrench. Use the special tool to hold the pinion flange while tightening the nut. - Rotate the pinion occasionally to make sure the differential pinion bearings seat correctly. Take frequent differential pinion bearing preload readings by rotating the pinion with a Nm (inch- pound) torque wrench. - If the preload recorded prior to disassembly is lower than the specification for used bearings, tighten the nut to specification. If the preload recorded prior to disassembly is higher than the specification for used bearings, tighten the nut to the original reading as recorded. - Refer to torque specifications for used pinion bearings in the Specifications portion of this section. 7. NOTE: Align the index marks. Install the four driveshaft flange to pinion flange bolts. 8. CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. To make sure that the yoke seats squarely on the flange, tighten the bolts evenly in a cross pattern as shown. CAUTION: If new bolts to retain the driveshaft to the axle flange are not available, coat the threads of the original bolts with threadlock and sealer. Tighten to specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Solid Rear Axle > Page 6090 9. CAUTION: To prevent interference with the rear disc brake caliper operation, install only the correct caliper bolt. NOTE: Make sure the stainless steel shoe slippers are correctly positioned. Install new slippers if worn or damaged. NOTE: Use the disc brake pad spreader to spread pads for reassembly. Install the rear disc brake caliper. 10. Install the rear wheel and tire assemblies. 11. Lower the vehicle. 12. Apply the brake pedal to make sure of rear disc brake caliper piston position. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Axle Shaft Assembly, Constant Velocity Type Axle Shaft: Specifications Driveshaft to Driveshaft Rear Axle Pinion Flange Bolts 83 ft.lb Front Driveshaft to Front Axle Bolts 11 - 15 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Axle Shaft Assembly, Constant Velocity Type > Page 6097 Axle Shaft: Specifications Maximum axle shaft end play 0.03 in Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 6098 Axle Shaft: Service and Repair Removal 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the differential housing cover. 1. Loosen the bolts and drain the lubricant from the rear axle housing. 2. Remove the bolts. 3. Remove the differential housing cover. 4. Remove the rear brake disc. 5. CAUTION: Turning the differential case or an axle shaft with the differential pinion shaft removed will cause the differential pinion gears to fall out of the assembly and damage the components. Remove the differential pinion shaft. 1. Remove the differential pinion shaft lock bolt. 2. Remove the differential pinion shaft. 6. CAUTION: Do not damage the rubber O-ring in the U-washer groove. Remove the U-washer. 1. Push the axle shaft inboard. 2. Remove the U-washer. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 6099 7. Reinstall the differential pinion shaft. 1. Install the differential pinion shaft. 2. Install the differential pinion shaft lock bolt finger-tight. 8. CAUTION: Do not damage the wheel bearing oil seal. Remove the axle shaft. Installation 1. Lubricate the lip of the wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 2. CAUTION: Turning the differential case or an axle shaft with the differential pinion shaft removed will cause the differential pinion gears to fall out of the assembly and damage the components. Remove the differential pinion shaft. 1. Remove the differential pinion shaft lock bolt. 2. Remove the differential pinion shaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 6100 3. CAUTION: Do not damage the wheel bearing oil seal. Install the axle shaft. 4. CAUTION: Do not damage the rubber O-ring in the U-washer groove. Install the U-washer. 1. Position the U-washer on the button end of the axle shaft. 2. Pull the axle shaft outward. 5. CAUTION: If a new pinion shaft lock bolt is unavailable, coat the threads with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5. Install the differential pinion shaft. 1. Align the hole in the differential pinion shaft with the differential pinion shaft lock bolt hole. 2. Install a new differential pinion shaft lock bolt. 6. Install the rear brake disc. 7. Install the differential housing cover, and fill the rear axle housing with the specified lubricant type and quantity. 8. Install the wheel and tire assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair Seals and Gaskets: Service and Repair Special Tools Special Tools Removal 1. Remove the axle shaft. 2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the rear wheel bearing and the inner wheel bearing oil seal at the same time. Note: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Page 6104 Using the special tools, remove the rear wheel bearing and wheel bearing oil seal together. Installation 1. Lubricate the new rear wheel bearing. - For 4.0L SOHC and 4.0L EI with limited slip rear axles and 5.0L vehicles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - For 4.0L SOHC and 4.0L EI with conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Lubricate the new rear wheel bearing. - For 4.0L SOHC and 4.0L EI with limited slip rear axles and 5.0L vehicles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - For 4.0L SOHC and 4.0L EI with conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check Wheel Bearing: Testing and Inspection Wheel Bearing Check 1. Raise and support the vehicle. ^ Make sure the system is warmed up to normal operating temperature, as thermal expansion can be the cause of a strain problem. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Spin the tire by hand to check the wheel bearings for roughness. NOTE: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. 3. Grip each front tire at the top and bottom arid move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check > Page 6110 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the service procedures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check > Page 6111 Wheel Bearing: Testing and Inspection Wheel Bearing Inspection 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the tire is off the floor. 2. Note: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel assembly. Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, perform one of the following actions. ^ On 4x2 vehicles, adjust the front wheel bearings. ^ On 4x4 vehicles, install a new wheel hub. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Solid Rear Axle Wheel Bearing: Service and Repair Solid Rear Axle Special Tools Special Tools Removal 1. Remove the axle shaft. 2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the rear wheel bearing and the inner wheel bearing oil seal at the same time. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Solid Rear Axle > Page 6114 Note: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and wheel bearing oil seal together. Installation 1. Lubricate the new rear wheel bearing. - For 4.0L SOHC and 4.0L EI with limited slip rear axles and 5.0L vehicles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - For 4.0L SOHC and 4.0L EI with conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Solid Rear Axle > Page 6115 Wheel Bearing: Service and Repair Independent Rear Suspension Wheel Bearing Removal And Installation 1. Remove the wheel knuckle. 2. CAUTION: Make sure that the press adapter outside diameter is slightly smaller than the hub outside diameter or damage to the knuckle will result. Using a suitable press, remove the hub from the bearing. - Discard the hub. 3. NOTE: The retainer ring is tapered and must be installed flat side down. Remove the retainer ring. - Discard the retainer ring. 4. Using a suitable press, remove the bearing from the wheel knuckle. - Discard the bearing. 5. CAUTION: The hub and bearing cannot be reused after disassembly. To install. reverse the removal Procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications - Tighten the spindle nut while rotating the brake disc and hub. - Loosen the spindle nut. - Tighten the spindle nut while rotating the brake disc and hub. - Install the following components: 1 Install the nut retainer. 2 Install the cotter pin. 3 Install the hub grease cap. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications Drive/Propeller Shaft: Specifications Rear driveshaft screws 70-95 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Diagrams > Driveshaft Drive/Propeller Shaft: Diagrams Driveshaft Driveshaft-Rear, 4X2 1 of 3 2 of 3 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Diagrams > Driveshaft > Page 6126 3 of 3 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Diagrams > Driveshaft > Page 6127 Drive/Propeller Shaft: Diagrams Universal Joints 1 of 2 2 of 2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Description and Operation > Universal Joints Drive/Propeller Shaft: Description and Operation Universal Joints The universal joints are: lubed-for-life design and require no lubrication. - equipped with nylon thrust washers, located at each base of the bearing cup, which control end play, position the needle bearing and improve grease movement. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Description and Operation > Universal Joints > Page 6130 Drive/Propeller Shaft: Description and Operation Driveshaft Note: Whenever the vehicle is raised on a hoist, inspect the universal joint slip yoke boot for rips or holes. Replace if required. Note: All driveshafts are balanced. If undercoating the vehicle, protect the driveshaft and universal joints to prevent application of any undercoating material. Note: The constant velocity (CV) joint on the front driveshaft is not serviceable. The front driveshaft is connected to the transfer case and the front drive axle by a driveshaft flange yoke. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft-Front Drive/Propeller Shaft: Service and Repair Driveshaft-Front Removal WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. With the vehicle in neutral, raise and support the vehicle. 2. Index-mark the front axle pinion flange to the front driveshaft. 3. Remove the transfer case skid plate. 4. Index-mark the transfer case pinion flange to the front driveshaft. 5. Remove the front driveshaft CV joint-to-transfer case bolts and washers. 6. Remove the front driveshaft-to-front axle bolts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft-Front > Page 6133 7. Note: Always disconnect the front driveshaft from the transfer case first. Remove the front driveshaft. Installation 1. Note: Install new front driveshaft CV joint-to-transfer case bolts and washers and new front driveshaft-to-front axle bolts and straps. If new bolts are not available, coat the threads of the original bolts with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5. Note: Always install the front driveshaft at the front axle first. To install, follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft-Front > Page 6134 Drive/Propeller Shaft: Service and Repair Driveshaft-Rear, 4X2 Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. With the vehicle in neutral, raise and support the vehicle. 2. Index-mark the driveshaft to driveshaft rear axle pinion flange. 3. Note: Index-mark the driveshaft slip yoke to the transmission output shaft. Remove the driveshaft. 1. Remove and discard the four bolts, and disconnect the driveshaft. 2. Lower the driveshaft, and slide the driveshaft rearward out of the transmission. - Plug the extension housing to prevent fluid loss. Installation 1. Note: Install new rear driveshaft-to-driveshaft rear axle pinion flange bolts. If new bolts are not available, coat the threads of the original bolts with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5. To install, follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft-Front > Page 6135 Drive/Propeller Shaft: Service and Repair Driveshaft-Rear, 4X4 Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. With the vehicle in neutral, raise and support the vehicle. 2. Index-mark the driveshaft yoke to the transfer case pinion flange. 3. Index-mark the driveshaft to driveshaft rear axle pinion flange. 4. Remove the four rear bolts, and disconnect the rear driveshaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft-Front > Page 6136 5. Separate the driveshaft from the transfer case. 1. Remove the four bolts. 2. Carefully remove the driveshaft. Installation 1. Note: Install new rear driveshaft-to-driveshaft rear axle pinion flange bolts and driveshaft flange yoke-to-transfer case bolts. If new bolts are not available, coat the threads of the original bolts with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5. To install, follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Service and Repair Slip Yoke: Service and Repair Special Tools Disassembly 1. Remove the driveshaft. 2. CAUTION: Do not clamp the driveshaft in the jaws of a vise or similar holding fixture. Remove the driveshaft slip yoke boot. 1. Index-mark the driveshaft to the driveshaft slip yoke. 2. With the rear driveshaft on a bench, cut and discard the driveshaft slip yoke boot clamps. 3. Separate the driveshaft slip yoke from the splined stub shaft on the driveshaft, and remove the driveshaft slip yoke boot. - Inspect the driveshaft slip yoke boot for damage and replace if required. 3. Inspect the lubricant for contamination. If contaminated, inspect the stub shaft and driveshaft slip yoke for wear. Replace the driveshaft as needed. Assembly 1. Slide the small opening end of the driveshaft slip yoke boot on the splined stub shaft as far as it will travel. 2. Install the small driveshaft slip yoke boot clamp and use Keystone Clamp Pliers to crimp the small driveshaft slip yoke boot clamp. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Service and Repair > Page 6140 3. Install the driveshaft slip yoke. 1. Lubricate the stub shaft splines, and pull the driveshaft slip yoke boot towards the driveshaft. - Use Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. 2. Fill the driveshaft slip yoke boot with approximately 10 grams of lubricant. - Use Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. 3. Position the large driveshaft slip yoke boot clamp. 4. Align the index marks made during disassembly, and install the driveshaft slip yoke. 4. Install the large driveshaft slip yoke boot clamp. 1. Remove any excess grease from the differential slip yoke boot and driveshaft slip yoke surfaces. 2. Position the driveshaft slip yoke boot over the driveshaft slip yoke boot groove. 3. Position the driveshaft slip yoke to specification from the driveshaft weld to the end of the slip yoke splines. 4. Bleed air from the driveshaft slip yoke boot. 5. Use Keystone Clamp Pliers to crimp the large driveshaft slip yoke boot clamp. 5. Install the driveshaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan, Flange Yoke Universal Joint: Service and Repair Single Cardan, Flange Yoke Special Tools Disassembly 1. Remove the driveshaft. 2. CAUTION: Do not clamp the driveshaft in a vise or similar holding fixture. Place the driveshaft on a suitable workbench, being careful not to damage the tube. 3. Note: If components are not marked and installed correctly, driveline imbalance can occur. Index-mark the positions of the driveshaft components. 4. Clamp the U joint tool in a vise. 5. Remove all four of the snap rings. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan, Flange Yoke > Page 6145 6. Remove the driveshaft flange yoke. 1. Position the driveshaft flange yoke in the U-joint tool. 2. Press out a bearing cup. 3. Remove the driveshaft flange yoke. 4. Press on the spider to remove the remaining bearing cup. 5. Remove the driveshaft flange yoke. 7. Remove the spider. 1. Reposition the driveshaft in the U-joint tool. 2. Press out the bearing cup. 3. Rotate the driveshaft. 4. Press on the spider to remove the remaining bearing cup. 5. Remove the spider. 8. Clean the yoke area at the end of the driveshaft. Assembly 1. Note: Universal joint kits are to be installed as complete assemblies only. Do not mix components from other U-joint kits. Install the spider. 1. Start a new bearing cup into the driveshaft yoke. - Check the needle bearings for correct positioning. 2. Position the new spider in the driveshaft yoke. 3. Position the driveshaft in the U joint tool. 4. Press the bearing cup to just below the snap ring groove. - Repeat for the other bearing cup. 2. Inspect the driveshaft flange yoke. Install new if necessary. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan, Flange Yoke > Page 6146 3. Install the driveshaft flange yoke. 1. Start a new bearing cup into the driveshaft flange yoke. - Check the needle bearings for correct positioning. 2. Position the driveshaft flange yoke. 3. Position the driveshaft in the U-joint tool. 4. Press the bearing cup to just below the snap ring groove. - Repeat for the other bearing cup. 4. Note: Use the yellow snap rings supplied in the kit to assemble the universal joint (U-joint). If difficulty is encountered with the yellow snap rings, install the black snap rings. Remove the driveshaft from the U-joint tool, and install the four snap rings. 5. Note: Do not strike the bearings. Check the U-joints for freedom of movement. If binding, strike the yoke with a brass or plastic hammer. 6. Install the driveshaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan, Flange Yoke > Page 6147 Universal Joint: Service and Repair Universal Joint -Single Cardan Special Tools Disassembly 1. CAUTION: Under no circumstances is the driveshaft assembly to be clamped in the jaws of a vise or similar holding fixture. Denting or localizing fracture can result, causing driveshaft failure during vehicle operation. Place the driveshaft on a suitable workbench. Be careful not to damage the tube. 2. Note: If components are not marked and therefore installed incorrectly, driveline imbalance can occur. Index-mark the driveshaft components. 3. Clamp U-joint tool in a vise. 4. Remove all four of the snap rings. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan, Flange Yoke > Page 6148 5. Note: If necessary, use a pair of pliers to remove a bearing cup if it cannot be pressed out all the way. Remove the driveshaft slip-yoke. 1. Position the driveshaft slip-yoke in the U-joint tool. 2. Press out a bearing cup. 3. Rotate the driveshaft slip-yoke. 4. Press on the spider to remove the remaining bearing cup. 5. Remove the driveshaft slip-yoke. 6. Repeat Step 5 to remove the remaining bearing cups and spider from the driveshaft. 7. Clean the yoke area at each end of the driveshaft. Assembly 1. Note: Universal Joint Service Kits are to be installed as complete assemblies only. Do not mix components from other U-Joint Kits. Install the bearing cup. 1. Start a new bearing cup into the driveshaft yoke. Check the needle bearings for correct positioning. 2. Position the new spider in the driveshaft yoke. 3. Using the U-joint tool, press the bearing cup to just below the snap ring groove. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan, Flange Yoke > Page 6149 2. Note: Use the yellow snap rings supplied in the kit to assemble the universal joint (U-joint). If difficulty is encountered with the yellow snap rings, install the black snap rings. Remove the driveshaft from the U joint tool, and install the snap ring. 3. Repeat Steps 1 and 2 to install the opposite side of the driveshaft yoke. 4. Inspect the driveshaft slip-yoke. Install a new yoke, if necessary. 5. Repeat Steps 1 and 2 to install the remaining new bearing cups, spider, driveshaft slip-yoke, and the snap rings. 6. Note: Do not strike the bearings. Check the U-joints for freedom of movement. If binding, strike the yoke with a brass or plastic hammer. 7. Install the driveshaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Flywheel Bolts Stage 1 13 Nm (10 ft.lbs.) Special bolts are used for flywheel installation; do not use standard bolts. Stage 2 71 Nm (52 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 6153 Flex Plate: Service and Repair Removal 1. Remove the transmission. 2. Remove the flywheel. 3. Clean and inspect the flywheel. Installation 1. Note: Special bolts are used for flywheel installation; do not use standard bolts. Install the flywheel. Tighten the bolts in the sequence shown in two stages. - Stage 1: Tighten to 13 Nm (10 ft. lbs.). - Stage 2: Tighten 71 Nm (52 ft. lbs.). 2. Install the transmission. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications Flywheel Bolts 75 - 85 ft.lb Flywheel Runout 0.005 in Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair > Dowels - Flywheel Flywheel: Service and Repair Dowels - Flywheel Removal 1. Note: Take care not to damage the flywheel dowel holes or surface areas around the flywheel dowel during removal. Remove the flywheel dowels by using a drift pin where the flywheel dowel is installed in an open hole, and locking pliers where the flywheel dowel is installed in a blind hole. Installation 1. Note: Care should be taken to drive the flywheel dowel squarely into place until fully seated and to not damage surrounding surface areas. Install all flywheel dowels by driving them into place using a brass or plastic mallet. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair > Dowels - Flywheel > Page 6159 Flywheel: Service and Repair Flywheel - Removal and Installation Special Tools Removal 1. Remove the clutch disc and pressure plate. 2. CAUTION: Two bolts should be loosened but left in to prevent the flywheel from falling. Remove six of eight bolts. Loosen the two remaining bolts but leave in place. 3. Press the flywheel off the crankshaft. - Install the two bolts in the threaded holes in the flywheel and remove flywheel. 4. Remove the bolts remaining in the crankshaft. 5. Remove the flywheel. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair > Dowels - Flywheel > Page 6160 1. Position the flywheel onto the crankshaft and install the flywheel-to-crankshaft bolts. - Apply Threadlock and Sealer EOAZ-1955AA or equivalent meeting Ford specification WSK-M2G315-A5 (Type II) to bolt threads. 2. Install the disc and pressure plate. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations > Page 6166 Overdrive Indicator Lamp: Description and Operation Overdrive (O/D) Off The O/D OFF indicator illuminates when the transmission is locked out of O/D. This dual function indicator will also flash off and on if a transmission malfunction is detected. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Locations > Page 6170 Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the gearshift lever in the (D) position. - Rotate the gearshift lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (D) position). 3. Hang a 3.6 kg (8 lb.) weight on the gearshift lever. 4. Center the pointer in the middle of the (D) position. - Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer. 5. Remove the 3.6 kg (8 lb.) weight. 6. Carefully move the gearshift lever from detent to detent and compare with the transmission settings. - Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation TRANSMISSION CONTROL INDICATOR LAMP The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to Transmission Control Switch, PCM Inputs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Service and Repair Bell Housing: Service and Repair Removal 1. Note: Take care not to damage the flywheel housing-to-block dowel holes or surface areas around the flywheel housing-to-block dowel hole during removal. Remove the flywheel housing-to-block dowels using a drift pin where the flywheel housing-to-block dowel is installed in an open hole, and locking pliers where the flywheel housing-to-block dowel is installed in a blind hole. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Specifications Case: Specifications Case Cover Bolts 12 - 16 ft.lb Case Plug 30 - 43 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Countershaft, M/T > Component Information > Specifications Countershaft: Specifications Countershaft Locknut 94 - 144 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Drain Plug, M/T > Component Information > Specifications Drain Plug: Specifications Drain Plug 30 - 43 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Specifications Extension Housing: Specifications Torque Specifications Extension Housing Bolts ........................................................................................................................................................... 32-46 Nm (24-33 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Specifications > Page 6194 Extension Housing: Service and Repair Special Tools Removal 1. If equipped, turn the air suspension switch off. 2. Disconnect the battery ground cable. 3. Raise and support the vehicle. 4. On 4WD vehicles, remove the transfer case. 5. Drain the transmission fluid. 6. Note: To maintain initial driveshaft balance, mark the driveshaft centering socket yoke and rear axle universal joint flange so they may be installed in their original positions. Mark the driveshaft centering socket yoke and rear axle universal joint flange. 7. Remove and support the rear driveshaft. 1. Remove the bolts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Specifications > Page 6195 2. Remove the rear driveshaft. 8. Use the (A) Hi-Lift Jack to support the (B) transmission. - Secure the (B) transmission with the (C) strap. 9. Remove the nuts. 10. Remove the crossmember. 1. Remove the six bolts (three each side). 2. Remove the crossmember. 11. Remove the (RH) transmission mount bolt. 1. Remove the bolt. 2. Reposition the exhaust mounting bracket. 12. Lower the transmission to access extension housing bolts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Specifications > Page 6196 13. Use the Seal Remover to remove the extension housing seal. 14. Remove the extension housing. 1. Remove the bolts. 2. Remove the extension housing. Installation 1. Note: The extension housing must be installed within four minutes after applying silicone. Apply a small bead of Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A to the surface of the case. 2. Install the extension housing. 1. Position the extension housing. 2. Install the bolts. 3. Use Extension Housing Seal Replacer to install the extension housing seal. 4. Raise and position the transmission. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Specifications > Page 6197 5. Install the (RH) transmission mount bolt. 1. Position the exhaust bracket. 2. Install the bolt. 6. install the crossmember. 1. Position the crossmember. 2. Install the six bolts and nuts (three each side). 7. Remove the Hi-Lift Jack. 8. Install the nuts. 9. Note: To maintain initial driveshaft balance, align marks on the rear driveshaft centering socket yoke and rear axle universal joint flange made during removal. Install the rear driveshaft. 1. Position the rear driveshaft. 2. Install the four bolts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Specifications > Page 6198 10. Fill the (A) transmission with MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or DDX or equivalent meeting Ford MERCON specification until it reaches the bottom of the (B) fill port and install the (C) case plug. 11. Lower the vehicle. 12. Connect the battery ground cable. 13. If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fill Plug, M/T > Component Information > Specifications Fill Plug: Specifications Fill Plug 30 - 43 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 SOHC VIN K SFI (2001)) 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 6206 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 SOHC VIN K SFI (2001)) 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 6207 Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Manual Transmission Capacity ............................................................................................................................................... ................................................................... 2.7 Quarts Note: Approximate refill. Service refill capacity is determined by filling the transmission to the bottom of the filler hole with the vehicle on a level surface. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 6210 Fluid - M/T: Fluid Type Specifications Manual Transmission Fluid .................................................................................................................. ............................................................. Mercon ATF Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Flywheel Gear, M/T > Component Information > Service and Repair Flywheel Gear: Service and Repair Removal WARNING: This procedure should be performed only by a properly equipped and experienced acetylene torch operator. To avoid personal injury, use tongs or wear welding gloves and safety goggles when handling the heated flywheel ring gear. 1. Remove the flywheel. 2. CAUTION: Do not heat the flywheel ring gear beyond 278°C (500°F). Use heat indicating crayons to prevent over heating. CAUTION: Tap the flywheel ring gear evenly to prevent binding. Remove the flywheel ring gear from the flywheel. Evenly heat the flywheel ring gear and use a brass drift to drive the flywheel ring gear off the flywheel. Installation WARNING: This procedure should be performed only by a properly equipped and experienced acetylene torch operator. To avoid personal injury, use tongs or wear welding gloves and safety goggles when handling the heated flywheel ring gear. 1. CAUTION: Do not heat the flywheel ring gear beyond 278°C (500°F). Use heat indicating crayons to prevent over heating. CAUTION: Keep the torch moving to prevent hot spots. Evenly heat the flywheel ring gear. 2. Install the flywheel ring gear. - The bevel on the flywheel ring gear must face the rear of the flywheel. - Use a brass drift. 3. Install the flywheel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Ring, M/T > Component Information > Specifications Synchronizer Ring: Specifications Synchronizer Blocking Ring to Gear mm (in) ................................................................................................................................................. 1.5 (0.059) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Specifications Output Shaft: Specifications Output Shaft Maximum Runout mm (in) ....................................................................................................................................................... 0.05 (0.002) Output Shaft Locknut ........................................................................................................................................................ 216-274 Nm (160-202 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Reverse Idler Gear > Component Information > Specifications Reverse Idler Gear: Specifications Reverse Idler Gear End Play ........................................................................................................................................ 0.1-0.2 mm (0.0039-0.0078 inch) Reverse Idler Shaft Bolt ........................................................................................................................................................... 79-117 Nm (58-86 ft. lbs.) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Turbine shaft speed (TSS) sensor screw 71 - 97 in.lb Output shaft speed sensor (OSS) sensor screw 71 - 97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications > Page 6228 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > 4R70W Transmission Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > 4R70W Transmission > Page 6231 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6232 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Transfer Case - Automatic Shift Transmission Speed Sensor: Service and Repair Transfer Case - Automatic Shift Output Shaft Speed Sensor-Front Removal 1. Remove the transfer case shift motor. 2. Remove the front output shaft speed sensor. 1. Remove the bolt. 2. Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Output Shaft Speed Sensor-Rear Removal Warning: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. 1. Raise and support vehicles. 2. Disconnect the electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Transfer Case - Automatic Shift > Page 6235 3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector. 1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover. 4. Remove the bolt and the sensor. Installation 1. Caution: Make sure the sensor seats flat against the boss To install, reverse the removal procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Transfer Case - Automatic Shift > Page 6236 Transmission Speed Sensor: Service and Repair 5R55E Removal 1. Raise and support the vehicle. 2. Disconnect output shaft speed (OSS) sensor electrical connector. 3. Remove OSS sensor. 1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission. - Inspect the OSS sensor O-ring for damage. If damaged, replace the O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Transfer Case - Automatic Shift > Page 6237 2. Connect OSS sensor electrical connector. 3. Lower the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Fork, M/T > Component Information > Specifications Shift Fork: Specifications Shift Fork to Synchronizer Sleeve 0.031 in Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Specifications Shifter M/T: Specifications Gearshift Lever Bolt 20 - 29 ft.lb Inner Gearshift Lever Boot Bolts 89 - 123 in.lb Outer Gearshift Lever Boot Screws 45 - 79 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Specifications > Page 6244 Shifter M/T: Service and Repair Removal 1. Remove the gearshift lever. 1. Lift the outer gearshift lever boot. 2. Remove the bolt. 3. Remove the gearshift lever. 2. Remove the inner gearshift lever boot. 1. Remove the four screws. 2. Remove the inner gearshift lever boot. Installation 1. Install the inner gearshift lever boot. 1. Position the inner gearshift lever boot. 2. Install the screws. 2. Install the gearshift lever. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Specifications > Page 6245 1. Position the gearshift lever. 2. Install the bolt. 3. Install the screws. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Specifications Transmission Mount: Specifications Transmission Mount Bolts 64 - 81 ft.lb Transmission Mount Nuts 64 - 81 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Turbine shaft speed (TSS) sensor screw 71 - 97 in.lb Output shaft speed sensor (OSS) sensor screw 71 - 97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Specifications > Page 6252 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Diagrams > 4R70W Transmission Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Diagrams > 4R70W Transmission > Page 6255 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6256 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Transfer Case - Automatic Shift Transmission Speed Sensor: Service and Repair Transfer Case - Automatic Shift Output Shaft Speed Sensor-Front Removal 1. Remove the transfer case shift motor. 2. Remove the front output shaft speed sensor. 1. Remove the bolt. 2. Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Output Shaft Speed Sensor-Rear Removal Warning: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. 1. Raise and support vehicles. 2. Disconnect the electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Transfer Case - Automatic Shift > Page 6259 3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector. 1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover. 4. Remove the bolt and the sensor. Installation 1. Caution: Make sure the sensor seats flat against the boss To install, reverse the removal procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Transfer Case - Automatic Shift > Page 6260 Transmission Speed Sensor: Service and Repair 5R55E Removal 1. Raise and support the vehicle. 2. Disconnect output shaft speed (OSS) sensor electrical connector. 3. Remove OSS sensor. 1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission. - Inspect the OSS sensor O-ring for damage. If damaged, replace the O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Transfer Case - Automatic Shift > Page 6261 2. Connect OSS sensor electrical connector. 3. Lower the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair Control Module: Service and Repair Removal 1. Remove the transmission control switch (TCS). 1. Remove the TCS cover. 2. Remove the TCS. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital transmission range (TR) sensor screws 71 - 97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6275 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6276 Digital Transmission Range Sensor: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6277 Digital Transmission Range Sensor: Service and Repair Special Tools Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the shift cable. 1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the bracket. 4. Disconnect the digital transmission range (TR) sensor electrical connector. 5. Remove the manual control outer lever nut and manual control outer lever. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6278 6. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor. 1. Position the digital TR sensor. 2. Loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Note: The manual lever must he in the neutral position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever. 1. Install the manual control outer lever. 2. Install the manual control outer lever nut. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6279 4. Connect the digital transmission range (TR) sensor electrical connector. 5. Connect the shift cable. 1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. Connect the battery ground cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Turbine shaft speed (TSS) sensor screw 71 - 97 in.lb Output shaft speed sensor (OSS) sensor screw 71 - 97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 6283 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Speed 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6286 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6287 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6288 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6289 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6290 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6291 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6292 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6293 Transmission Speed Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6294 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6295 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6296 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6297 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6299 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6300 Transmission Speed Sensor: Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6301 Diagram 29-4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 6302 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Transfer Case Automatic Shift Transmission Speed Sensor: Service and Repair Transfer Case - Automatic Shift Output Shaft Speed Sensor-Front Removal 1. Remove the transfer case shift motor. 2. Remove the front output shaft speed sensor. 1. Remove the bolt. 2. Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Output Shaft Speed Sensor-Rear Removal Warning: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. 1. Raise and support vehicles. 2. Disconnect the electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Transfer Case Automatic Shift > Page 6305 3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector. 1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover. 4. Remove the bolt and the sensor. Installation 1. Caution: Make sure the sensor seats flat against the boss To install, reverse the removal procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Transfer Case Automatic Shift > Page 6306 Transmission Speed Sensor: Service and Repair 5R55E Removal 1. Raise and support the vehicle. 2. Disconnect output shaft speed (OSS) sensor electrical connector. 3. Remove OSS sensor. 1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission. - Inspect the OSS sensor O-ring for damage. If damaged, replace the O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Transfer Case Automatic Shift > Page 6307 2. Connect OSS sensor electrical connector. 3. Lower the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations The Transmission Fluid Temperature Sensor is located on the main control body wiring harness assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6313 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6314 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6315 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6316 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6317 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6318 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6319 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6320 Transmission Temperature Sensor/Switch: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6321 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6322 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6323 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6324 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6325 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6326 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6327 Diagram 29-4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 6328 Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference voltage signal. The resistance in the TFT varies with temperature. The powertrain control module (PCM) monitors the voltage signal across the TFT, and uses this information to determine the transmission fluid temperature. The TFT is located on the main control body wiring harness assembly. The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation and electronic pressure control (EPC). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications Transmission Speed Sensor: Specifications Turbine shaft speed (TSS) sensor screw 71 - 97 in.lb Output shaft speed sensor (OSS) sensor screw 71 - 97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications > Page 6333 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > 4R70W Transmission Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > 4R70W Transmission > Page 6336 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6337 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Transfer Case Automatic Shift Transmission Speed Sensor: Service and Repair Transfer Case - Automatic Shift Output Shaft Speed Sensor-Front Removal 1. Remove the transfer case shift motor. 2. Remove the front output shaft speed sensor. 1. Remove the bolt. 2. Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Output Shaft Speed Sensor-Rear Removal Warning: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. 1. Raise and support vehicles. 2. Disconnect the electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Transfer Case Automatic Shift > Page 6340 3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector. 1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover. 4. Remove the bolt and the sensor. Installation 1. Caution: Make sure the sensor seats flat against the boss To install, reverse the removal procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Transfer Case Automatic Shift > Page 6341 Transmission Speed Sensor: Service and Repair 5R55E Removal 1. Raise and support the vehicle. 2. Disconnect output shaft speed (OSS) sensor electrical connector. 3. Remove OSS sensor. 1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission. - Inspect the OSS sensor O-ring for damage. If damaged, replace the O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Transfer Case Automatic Shift > Page 6342 2. Connect OSS sensor electrical connector. 3. Lower the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Pressure Regulating Solenoid: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 6357 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 6358 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 6359 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Pressure Regulating Solenoid: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6362 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6363 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6364 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6365 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6366 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6367 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6368 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6369 Pressure Regulating Solenoid: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6370 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6371 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6372 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6373 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6374 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6375 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6376 Diagram 29-4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 6377 Pressure Regulating Solenoid: Description and Operation Electronic Pressure Control (EPC) Solenoid The electronic pressure control (EPC) solenoid is a variable force style (VFS) solenoid. The VFS type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve. The powertrain control module varies the current to the EPC solenoid. This action causes the solenoid to regulate transmission line pressure and line modulator pressure. This is done by producing resisting forces to the main regulator and line modulator circuits. These two solenoids control clutch application pressures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 6378 Pressure Regulating Solenoid: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. Loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 7. Note: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 6379 8. Disconnect the appropriate solenoid electrical connector. 1. Disconnect shift solenoids electrical connectors. 2. Disconnect the torque converter clutch (TCC) solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid electrical connector. 9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. CAUTION: Shift solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the appropriate solenoid(s). Installation 1. Install the new solenoid(s). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 6380 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the torque converter clutch (TCC) solenoid electrical connector. 3. Connect the electrical pressure control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1. Install the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 6381 2. Install the transmission fluid filter screw. 6. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. - Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. Connect the battery ground cable. 11. Fill the transmission to the proper fluid level and check for proper transmission operation. - Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications Shift Lock Actuator Bolts 62.5-98 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 6385 Shift Interlock Solenoid: Service and Repair Removal 1. Remove the steering column assembly. 2. Remove the insert plate and shift lock actuator. 1. Remove the bolts. 2. Remove the insert plate and shift lock actuator. 3. Note: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced. Remove the insert plate from the shift lock actuator. Remove and discard the shift lock actuator clip. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Shift Solenoid: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 6389 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 6390 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 6391 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6394 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6395 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6396 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6397 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6398 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6399 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6400 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6401 Shift Solenoid: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6402 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6403 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6404 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6405 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6406 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6407 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6408 Diagram 29-4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 6409 Shift Solenoid: Description and Operation Shift Solenoids A, B, C, and D Four On/Off shift solenoids allow the powertrain control module to control shift scheduling. - The solenoids are two-way, normally open style. - The shift solenoids (SSA, SSB, SSC, and SSD) provide gear selection by controlling the pressures of the shift valves. - SSD is also used to apply and release the coast clutch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 6410 Shift Solenoid: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. Loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 7. Note: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 6411 8. Disconnect the appropriate solenoid electrical connector. 1. Disconnect shift solenoids electrical connectors. 2. Disconnect the torque converter clutch (TCC) solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid electrical connector. 9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. CAUTION: Shift solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the appropriate solenoid(s). Installation 1. Install the new solenoid(s). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 6412 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the torque converter clutch (TCC) solenoid electrical connector. 3. Connect the electrical pressure control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1. Install the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 6413 2. Install the transmission fluid filter screw. 6. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. - Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. Connect the battery ground cable. 11. Fill the transmission to the proper fluid level and check for proper transmission operation. - Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Bolt 80-97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 6417 Torque Converter Clutch Solenoid: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 6418 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 6419 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 6420 SSA, SSC solenoids 1. TCC solenoid 2. SSB, SSD solenoids 3. EPC solenoid Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6423 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6424 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6425 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6426 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6427 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6428 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6429 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6430 Torque Converter Clutch Solenoid: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6431 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6432 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6433 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6434 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6435 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6436 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6437 Diagram 29-4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6438 Torque Converter Clutch Solenoid: Description and Operation Torque Converter Clutch (TCC) Solenoid The torque converter clutch (TCC) solenoid is used to control the apply and release of the TCC. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6439 Torque Converter Clutch Solenoid: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. Loosen the nut and position the heat shield out of the way. 4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid. 6. Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 7. Note: Main control assembly does not need to be removed for solenoid service. Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6440 8. Disconnect the appropriate solenoid electrical connector. 1. Disconnect shift solenoids electrical connectors. 2. Disconnect the torque converter clutch (TCC) solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid electrical connector. 9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may damage the solenoid or converter modulator valve. CAUTION: Shift solenoid (SSC) may pop out of its bore. This may damage the solenoid. Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3. Remove the solenoid clamp. 4. Remove the appropriate solenoid(s). Installation 1. Install the new solenoid(s). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6441 2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install the solenoid clamp screws. 3. Connect the six solenoid electrical connectors. 1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the torque converter clutch (TCC) solenoid electrical connector. 3. Connect the electrical pressure control (EPC) solenoid electrical connector. 4. CAUTION: Excessive pressure may break the retaining pins. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector. 5. Install the transmission fluid filter. 1. Install the transmission fluid filter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 6442 2. Install the transmission fluid filter screw. 6. Install the transmission fluid pan. 1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install the transmission fluid pan. - Loosely install the transmission fluid pan screws. 7. Tighten the transmission fluid pan screws. 8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle. 10. Connect the battery ground cable. 11. Fill the transmission to the proper fluid level and check for proper transmission operation. - Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations > Page 6448 Overdrive Indicator Lamp: Description and Operation Overdrive (O/D) Off The O/D OFF indicator illuminates when the transmission is locked out of O/D. This dual function indicator will also flash off and on if a transmission malfunction is detected. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Locations > Page 6452 Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the gearshift lever in the (D) position. - Rotate the gearshift lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (D) position). 3. Hang a 3.6 kg (8 lb.) weight on the gearshift lever. 4. Center the pointer in the middle of the (D) position. - Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer. 5. Remove the 3.6 kg (8 lb.) weight. 6. Carefully move the gearshift lever from detent to detent and compare with the transmission settings. - Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation TRANSMISSION CONTROL INDICATOR LAMP The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to Transmission Control Switch, PCM Inputs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Service and Repair Control Module: Service and Repair Removal 1. Remove the transmission control switch (TCS). 1. Remove the TCS cover. 2. Remove the TCS. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital transmission range (TR) sensor screws 71 - 97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6473 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6474 Digital Transmission Range Sensor: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6475 Digital Transmission Range Sensor: Service and Repair Special Tools Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect the shift cable. 1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the bracket. 4. Disconnect the digital transmission range (TR) sensor electrical connector. 5. Remove the manual control outer lever nut and manual control outer lever. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6476 6. Remove the screws and the digital TR sensor. Installation 1. Install the digital TR sensor. 1. Position the digital TR sensor. 2. Loosely install the screws. 2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. Note: The manual lever must he in the neutral position. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence. 3. Install the manual control outer lever. 1. Install the manual control outer lever. 2. Install the manual control outer lever nut. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6477 4. Connect the digital transmission range (TR) sensor electrical connector. 5. Connect the shift cable. 1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever. 6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. Connect the battery ground cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Specifications Transmission Speed Sensor: Specifications Turbine shaft speed (TSS) sensor screw 71 - 97 in.lb Output shaft speed sensor (OSS) sensor screw 71 - 97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Specifications > Page 6481 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions Transmission Speed 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 SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 6484 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 6485 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 6486 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 6487 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 6488 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 6489 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 6490 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 6491 Transmission Speed Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 6492 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 6493 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 6494 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 6495 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 6496 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 6497 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 6498 Transmission Speed Sensor: Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Diagram Information and Instructions > Page 6499 Diagram 29-4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Page 6500 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Service and Repair > Transfer Case - Automatic Shift Transmission Speed Sensor: Service and Repair Transfer Case - Automatic Shift Output Shaft Speed Sensor-Front Removal 1. Remove the transfer case shift motor. 2. Remove the front output shaft speed sensor. 1. Remove the bolt. 2. Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Output Shaft Speed Sensor-Rear Removal Warning: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. 1. Raise and support vehicles. 2. Disconnect the electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Service and Repair > Transfer Case - Automatic Shift > Page 6503 3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector. 1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover. 4. Remove the bolt and the sensor. Installation 1. Caution: Make sure the sensor seats flat against the boss To install, reverse the removal procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Service and Repair > Transfer Case - Automatic Shift > Page 6504 Transmission Speed Sensor: Service and Repair 5R55E Removal 1. Raise and support the vehicle. 2. Disconnect output shaft speed (OSS) sensor electrical connector. 3. Remove OSS sensor. 1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission. - Inspect the OSS sensor O-ring for damage. If damaged, replace the O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Service and Repair > Transfer Case - Automatic Shift > Page 6505 2. Connect OSS sensor electrical connector. 3. Lower the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations The Transmission Fluid Temperature Sensor is located on the main control body wiring harness assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6511 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6512 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6513 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6514 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6515 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6516 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6517 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6518 Transmission Temperature Sensor/Switch: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6519 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6520 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6521 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6522 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6523 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6524 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6525 Diagram 29-4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 6526 Transmission Temperature Sensor/Switch: Description and Operation Transmission Fluid Temperature (TFT) Sensor The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference voltage signal. The resistance in the TFT varies with temperature. The powertrain control module (PCM) monitors the voltage signal across the TFT, and uses this information to determine the transmission fluid temperature. The TFT is located on the main control body wiring harness assembly. The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation and electronic pressure control (EPC). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Specifications Transmission Speed Sensor: Specifications Turbine shaft speed (TSS) sensor screw 71 - 97 in.lb Output shaft speed sensor (OSS) sensor screw 71 - 97 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Specifications > Page 6531 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > 4R70W Transmission Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > 4R70W Transmission > Page 6534 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Diagrams > Page 6535 Transmission Speed Sensor: Description and Operation OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Service and Repair > Transfer Case - Automatic Shift Transmission Speed Sensor: Service and Repair Transfer Case - Automatic Shift Output Shaft Speed Sensor-Front Removal 1. Remove the transfer case shift motor. 2. Remove the front output shaft speed sensor. 1. Remove the bolt. 2. Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Output Shaft Speed Sensor-Rear Removal Warning: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. 1. Raise and support vehicles. 2. Disconnect the electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Service and Repair > Transfer Case - Automatic Shift > Page 6538 3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector. 1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover. 4. Remove the bolt and the sensor. Installation 1. Caution: Make sure the sensor seats flat against the boss To install, reverse the removal procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Service and Repair > Transfer Case - Automatic Shift > Page 6539 Transmission Speed Sensor: Service and Repair 5R55E Removal 1. Raise and support the vehicle. 2. Disconnect output shaft speed (OSS) sensor electrical connector. 3. Remove OSS sensor. 1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission. - Inspect the OSS sensor O-ring for damage. If damaged, replace the O-ring. Installation 1. Inspect and lubricate O-ring with petroleum jelly. 1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 > Service and Repair > Transfer Case - Automatic Shift > Page 6540 2. Connect OSS sensor electrical connector. 3. Lower the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Locations > Page 6546 ABS Light: Description and Operation The Antilock Brake System (ABS) uses the yellow ABS warning indicator to alert the driver of a malfunctions in the ABS. The yellow ABS warning indicator will come on to warn the driver that the ABS has been turned off due to a symptom that exists in the ABS. Normal power assist braking remains but wheels can lock during a panic stop while the yellow ABS warning indicator is illuminated. The diagnostic procedures must be followed step-by-step in order to correct the condition. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Differential Speed Sensor > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications Anti-lock brake control module bolts 1.8 - 1.9 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 6553 Electronic Brake Control Module: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 6554 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 6555 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 6556 Electronic Brake Control Module: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is part of, please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 6557 Electronic Brake Control Module: Service and Repair Removal 1. CAUTION: Prior to removal of the module, it is necessary to upload module configuration information to the scan tool. This information needs to be downloaded into the new module once installed. Disconnect the battery ground cable. 2. Remove the hydraulic control unit bolts. 3. Disconnect the anti-lock brake control module electrical connectors. 4. Remove the anti-lock brake control module. 1 Remove the bolts. 2 Remove the control module. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 6558 1. CAUTION: Once the new module is installed, it is necessary to download the module configuration information from the scan tool into the module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Brake line to (EHCU) nuts (M10-1) 12-16 ft.lb Brake line to (EHCU) nuts (M12-1) 15-18 ft.lb Electronic hydraulic control unit bolts 9-13 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6562 Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6563 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector by lifting up on the release tab. 3. Disconnect the brake lines from the hydraulic control unit (HCU). 4. Remove the HCU. 1 Remove the bolts. 2 Remove the HCU. 5. Remove the anti-lock brake control module. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6564 1. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes 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: 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. CAUTION: After the HCU is installed, it is necessary to bleed the hydraulic brake system. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Front anti-lock brake sensor bolt (4x2) 71 - 88 ft.lb Front anti-lock brake sensor wire retaining bolt (4x4) 62 - 80 ft.lb Front anti-lock brake sensor bolt (4x4) 62 - 80 ft.lb Rear anti-lock brake sensor bolt 20 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Left Front Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Left Front > Page 6570 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front Wheel Speed Sensor: Service and Repair Sensor, Front Removal 1. Raise and support the vehicle. 2. Disconnect the front anti-lock brake sensor wire from the vehicle frame. 1 Disconnect the electrical connector. 2 Unclip the front anti-lock brake sensor wire from the vehicle frame. 3. Remove the front anti-lock brake sensor. 1 Remove the bolt. 2 Remove the front ant1 -lock brake sensor. Installation 1. NOTE: Plug the sensor mount opening and thoroughly clean the mounting surface. Apply High Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A meeting Ford specification ESA-M1Cl98-A. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 6573 Wheel Speed Sensor: Service and Repair Sensor, Rear Removal 1. Raise and support vehicle. 2. NOTE: Clean off dirt and debris that may have collected around the rear anti-lock brake sensor before removal. Remove the rear anti-lock brake sensor. 1 Disconnect the rear anti-lock brake sensor electrical connector. 2 Remove the bolt. 3 Remove the rear anti-lock brake sensor. Installation 1. NOTE: Thoroughly clean the mounting surface. NOTE: Inspect the anti-lock brake sensor O-ring for damage; lightly lubricate the O-ring with High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications Caliper bleeder screw, rear 15 ft.lb Caliper bleeder screw, front 15 ft.lb Master cylinder bleeder screw 70-159 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding Brake Bleeding: Service and Repair Brake Caliper Bleeding 1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was disconnected. Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 4. Tighten the disc brake caliper bleeder screw. Refer to Specifications. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6579 Brake Bleeding: Service and Repair Brake System 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 eyes 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 brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 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. NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 4. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 5. Tighten the RH rear bleeder screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6580 6. Repeat Steps 2, 3, 4 and 5 for the LH rear bleeder screw. 7. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 8. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 9. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH front disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 10. Tighten the RH front disc brake caliper bleeder screw. 11. Repeat Steps 7, 8, 9 and 10 for the LH front disc brake caliper bleeder screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6581 Brake Bleeding: Service and Repair Brake System Pressure Bleeding 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. 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. Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose to the fitting on the adapter. 3. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Open the valve on the bleeder tank. 5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw and remove the rubber hose. 6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the RH front disc brake caliper bleeder screw ending with the LH front disc brake caliper bleeder screw. 7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6582 Brake Bleeding: Service and Repair Four Wheel ABS Hydraulic Control Unit (HCU) NOTE: This procedure only needs to be performed if the 4-wheel anti-lock brake (4WABS) hydraulic control unit (HCU) has been installed new. 1. Connect the scan tool DCL cable adapter into the vehicle data link connector (DLC) under the dash, and follow the scan tool instructions for bleeding. 2. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master cylinder reservoir with the specified brake fluid. 3. Connect a clear drain tube to the RH rear bleeder screw and the other end in a container partially filled with recommended brake fluid. 4. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 5. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 6. Tighten the bleeder screw. 7. Repeat Steps 3 - 6 for the LH rear bleeder screw, the RH front bleeder screw and the LH front bleeder screw, in that order. 8. Repeat the conventional bleed procedure as outlined in Steps 3 - 7. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6583 Brake Bleeding: Service and Repair Master Cylinder Priming - In-Vehicle or Bench Special Tools WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes 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 brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 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. NOTE: When any part of the hydraulic system has been disconnected for repair or installation, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: When the brake master cylinder has been installed new or the system has been emptied or partially emptied, it must be primed to prevent air from entering the system. 1. For in-vehicle priming, disconnect the brake lines from the brake master cylinder. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6584 2. For bench priming, mount the brake master cylinder in a vise. 3. Install short brake tubes with the ends bent into the brake master cylinder reservoir. ^ Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. 4. For a new brake master cylinder, remove the cruise switch. 5. Fill the cruise switch with the specified brake fluid. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6585 6. Install the cruise switch. 7. Slowly depress the primary piston or, for in-vehicle priming, have an assistant slowly pump the brake pedal until clear brake fluid flows from both brake tubes with no air bubbles. 8. If necessary, install the brake master cylinder into the vehicle. 9. Remove the short brake tubes and install the master cylinder outlet tubes. 10. Loosen a brake outlet tube at the 4WABS hydraulic control unit (HCU). 11. NOTE: Refill the brake master cylinder reservoir as necessary. Have an assistant depress and hold the brake pedal. 12. Tighten the outlet tube fitting at the HCU. 13. Repeat the above three steps until no air bubbles are seen in the expelled brake fluid. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6586 14. Repeat the above four steps for the remaining master cylinder outlet tube. 15. Connect one end of a flexible tube to the master cylinder bleeder screw. Submerge the other end in a container partially filled with the specified brake fluid. 16. Have an assistant pump and then hold firm pressure on the brake pedal. 17. NOTE: Refill the brake master cylinder reservoir as necessary. Loosen the master cylinder bleeder screw until brake fluid flows out of the drain tube. 18. Tighten the master cylinder bleeder screw. 19. Repeat the above three steps until there are no air bubbles in the expelled brake fluid. 20. Bleed the brake system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Page 6587 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications Brake Pedal Assy: Specifications Brake pedal bracket bolts and nuts 16 - 21 ft.lb Brake pedal bracket nuts 16 - 21 ft.lb Brake pedal pivot bolt and nut 15 - 25 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 6591 Brake Pedal Assy: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Brakes and Traction Control; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 6592 Brake Pedal Assy: Service and Repair Removal 1. NOTE: When removing the stoplight switch, retain the bushing and hairpin clip. They will be required for installation. Disconnect the brake booster push rod. 1 Remove the hairpin clip. 2 Separate the stoplight switch and the brake booster push rod from the brake pedal pin. 3 Remove the brake booster push rod bushing. 2. Remove the bulkhead sound insulator. 3. Remove the bolts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 6593 4. CAUTION: Support the brake master cylinder and power brake booster in the engine compartment. Remove the brake pedal assembly. 1 Remove the nuts. 2 Remove the brake pedal assembly. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications > Page 6594 1. Follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Locations > Page 6598 Brake Warning Indicator: Description and Operation Brake System The red brake warning light (BRAKE) is used to indicate a low fluid level, brake malfunction or a parking brake that is not fully released. The brake fluid level switch is located in the brake fluid reservoir. The yellow brake warning indicator is used to indicate a malfunction or deactivation of the Anti-lock Brake System (ABS). It illuminates when triggered by the ABS control module and stays illuminated as long as the malfunction remains in the system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Front Brake Caliper: Specifications Front disc brake caliper anchor plate bolts 72 - 97 ft.lb Disc brake caliper bolts 21 - 26 ft.lb Disc brake caliper bleeder screw 13-17 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Front > Page 6604 Brake Caliper: Specifications Brake caliper bolts 20 ft.lb Caliper flow bolt 23-29 ft.lb Disc brake caliper bleeder screw 13-17 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Brake Caliper: Service and Repair Front Caliper Removal and Installation Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle, This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes 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: 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. Disconnect the front brake hose. 1 Remove the front brake hose bolt. 2 Disconnect the front brake hose. 3 Remove and discard the copper washers. Plug the front brake hose. 4. Remove the disc brake caliper. 1 Remove the disc brake caliper bolts. 2 Lift the disc brake caliper off the front disc brake caliper anchor plate. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6607 5. Inspect the disc brake caliper for leaks. ^ If leaks are found, disassembly is required. Installation 1. Install the disc brake caliper. 1 Install the disc brake caliper. 2 Install the disc brake caliper bolts. 2. Install the front brake hose. ^ Use new copper washers; connect the front brake hose. ^ Install the front brake hose bolt. 3. Bleed the disc brake caliper. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the wheel and tire assembly. 5. Inspect the brake system operation. Caliper Disassembly and Assembly Disassembly 1. Remove the disc brake caliper. 2. Drain remaining brake fluid from the disc brake caliper. 3. Secure the disc brake caliper in a vise. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6608 4. Remove the caliper pistons. 1 Place a block of wood between the caliper bridge and the caliper pistons. 2 Apply low air pressure to the fluid port in the disc brake caliper. 3 Force out the caliper piston to the block of wood. 4 Remove the block of wood and the caliper pistons. 5. Remove and discard the piston seals and boots. 6. NOTE: Do not hone the caliper bores. Pistons are not available for honed caliper bores. If the caliper bores are excessively scored or corroded, install a new disc brake caliper. Assembly 1. CAUTION: Never reuse piston seals or dust boots. NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. Lubricate the piston boot, caliper piston, piston seal, and cylinder bores with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6609 2. Install the caliper pistons. 1 Install the piston seal. 2 Install the piston boot. 3 CAUTION: Be careful not to damage or dislodge the piston seal. Insert the caliper piston. 4 Press the caliper piston into the caliper bore, being careful not to cock the caliper piston. 3. Install the disc brake caliper. Brake Caliper Anchor Plate Removal 1. NOTE: AWD and 4x4 shown, 4x2 similar. Remove the pads. 2. Remove the front disc brake caliper anchor plate. 1 Remove the two front disc brake caliper anchor plate bolts. 2 Remove the front disc brake caliper anchor plate. Installation 1. Install the front disc brake caliper anchor plate. 1 Position the front disc brake caliper anchor plate. 2 Install the front disc brake caliper anchor plate bolts. 2. Install the pads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6610 Brake Caliper: Service and Repair Rear Caliper Removal and Installation Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes 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: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Disconnect the brake hose. 1 Remove bolt. 2 Disconnect the rear wheel brake hose. 3 Remove the copper washers and plug the brake hose. 4. CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The guide pins are meant to be sealed for life and are not repairable. Use Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A for re-lubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in contamination and accelerated corrosion or wear of the caliper slide pin mechanism. Remove the rear disc brake caliper. 1 Remove the brake caliper bolts. 2 Lift the rear disc brake caliper off the rear disc brake caliper anchor plate. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6611 5. Inspect the rear disc brake caliper for leaks. ^ If leaks are found, disassembly is required. Installation 1. CAUTION: To prevent interference with rear disc brake caliper operation, install only the correct caliper bolt. NOTE: Make sure the stainless steel shoe slippers are correctly positioned. Install new slippers if worn or damaged. NOTE: When installed, the locator notch on the brake pads will be located at the upper end of the rear disc brake caliper. Install the rear disc brake caliper. 2. Install the rear wheel brake hose. ^ Connect the brake hose and install the caliper flow bolt. ^ Use new copper washers. 3. Bleed the disc brake caliper. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the wheel and tire assembly. 5. Verify correct brake operation. Caliper Disassembly and Assembly Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6612 Disassembly 1. Remove the rear disc brake caliper. 2. Drain the remaining brake fluid from the rear disc brake caliper. 3. Secure the rear disc brake caliper in a vise. 4. Remove the rear disc brake piston. 1 Place a block of wood between the caliper bridge and the rear disc brake piston. 2 Apply low air pressure to the fluid port in the rear disc brake caliper. 3 Force the rear disc brake piston out to the block of wood. 4 Remove the block of wood and the rear disc brake piston. 5. NOTE: Do not hone the cylinder bore. Pistons are not available for honed cylinder bores. If the rear disc brake caliper cylinder bore/piston is excessively scored or corroded, install a new rear disc brake caliper. Remove and discard the piston seal and dust boot. Assembly CAUTION: Never reuse the piston seal or dust boot. NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6613 1. Lubricate the following with High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. ^ cylinder bore ^ piston seal ^ rear disc brake piston ^ dust boot 2. Install the piston seal. 3. Install the dust boot. 4. CAUTION: Be careful not to damage or dislodge the piston seal. Install the rear disc brake piston. 5. Install the rear disc brake caliper. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6614 Rear Disc Brake Adapter Removal 1. Disconnect the rear parking brake cable guide. 2. Remove the axle shaft. 3. Remove the bolts and the rear wheel disc brake adapter. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications Minimum thickness above the metal backing plate or rivets 0.10 in Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front Brake Pad: Service and Repair Front Removal 1. Remove brake fluid in the master cylinder reservoir until the reservoir is half full. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 4. CAUTION: Install a new pad if worn to or past the specified thickness above the metal backing plate or rivets. Install new pads in complete axle sets. Inspect the pads for wear or contamination. 5. Remove the lower caliper bolt. 6. Rotate the disc brake caliper upward. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6620 7. Remove the pads and the stainless slippers. 1 Remove the pads. 2 Remove the stainless slippers. 8. On 4x2 vehicles, measure the brake disc and hub for minimum thickness. ^ Machine the brake disc first then, install a new brake disc and hub if not within specification. 9. On 4x4 vehicles, measure the brake disc for minimum thickness and for lateral runout. ^ Machine the brake disc first then, install a new brake disc if not within specification. 10. Inspect the disc brake caliper for leaks. ^ If leaks are found, disassembly is required. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6621 1. NOTE: Use a suitable suction device to remove brake fluid from the master cylinder. NOTE: Clean the anchor plate and stainless slipper surfaces. NOTE: The inboard pad has a wear indicator tab. Install the stainless slippers and the pads. 1 Install the stainless slippers. 2 Install the pads. 2. Inspect the anti-rattle spring, install a new spring if worn or damaged. 3. NOTE: If installing new pads, the caliper pistons must be compressed using a C-clamp and a wooden block. Lower the brake fluid level in the master cylinder if required. Rotate the disc brake caliper downward. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6622 4. Install the caliper bolt. 5. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the wheel and tire assembly. 6. Inspect the brake system operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6623 Brake Pad: Service and Repair Rear Removal 1. Remove brake fluid in the master cylinder reservoir until the reservoir is half full. 2. CAUTION: Replace the pads if worn to or past the specified thickness above the metal backing plate or rivets. Install new pads in complete axle sets. Inspect the brake pads for wear or contamination. Install new pads if worn to or past specification. 3. NOTE: It is not necessary to remove the rear wheel brake hose when performing this procedure. Remove the rear disc brake caliper. 4. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the brake pads. Remove the brake pads. 5. Retract the caliper piston into the rear disc brake caliper. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6624 6. Remove the slippers. 7. CAUTION: Use a hub-mount brake lathe if necessary to machine the rear brake disc. Measure the rear brake disc, and resurface as necessary. Install a new rear brake disc if beyond specification. Installation 1. Clean the slipper mating surface, and install the slippers. 2. CAUTION: Install new brake pads in full axle sets. Do not install new brake pads on only one side of vehicle. Install the brake pads. 3. Install the rear disc brake caliper. 4. Verify correct brake operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Brake Rotor/Disc Brake Rotor/Disc: Specifications Brake Rotor/Disc .............................................................................................................................................................. ........................................................ Min Thickness Front .................................................................................................................................................... ............................................. 0.9646 inch (24.50mm) Rear ..................................................................................................................................................... .................................................. 0.4331 inch (11mm) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Brake Rotor/Disc > Page 6629 Brake Rotor/Disc: Specifications Brake disc shield bolts 7-10 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor/Disc: Service and Repair Front Brake Disc Removal 1. Remove the front disc brake caliper anchor plate. 2. On 4x4 vehicles, remove the brake disc. 3. On 4x2 vehicles, remove the brake disc and hub as follows: 1 Remove the hub grease cap. 2 Remove the cotter pin. 3 Remove the nut retainer. 4 Remove the spindle nut. 5 Remove the front wheel outer bearing retainer washer. 6 Remove the outer front wheel bearing. 7 Remove the brake disc and hub. 4. Remove the wheel hub grease seal. Remove the front wheel bearing. Installation 1. On AWD and 4x4 vehicles, position the brake disc to the wheel hub. Use Metal Brake Parts Cleaner F3AZ-19579-SA or equivalent to clean the brake disc. 2. On 4x2 vehicles, thoroughly clean and inspect the front wheel bearings and the brake disc and hub. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 6632 ^ Use Metal Brake Parts Cleaner F3AZ-19579-SA or equivalent. 3. On 4x2 vehicles, lubricate the front wheel bearings. ^ Use Premium Long-Life Grease XG-1-C or-K or equivalent meeting Ford specification ESA-M1C75-B. 4. On 4x2 vehicles, install a new wheel hub grease seal. 1 Install the inner front wheel bearing. 2 Install a new wheel hub grease seal. 5. On 4x2 vehicles, install the brake disc and hub. 1 Position the brake disc and hub. 2 Install the outer front wheel bearing. 3 Install the front wheel outer bearing retainer washer. 4 Install the spindle nut. 6. Tighten the spindle nut while rotating the brake disc and hub. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 6633 7. Loosen the spindle nut. 8. Tighten the spindle nut while rotating the brake disc and hub. 9. On 4x2 vehicles, install the following components: 1 Install the nut retainer. 2 Install the cotter pin. 3 Install the hub grease cap. 10. Install the front disc brake caliper anchor plate. Brake Disc Shield Removal 1. Remove the brake disc. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 6634 2. Remove the brake disc shield. 1 Remove the bolts. 2 Remove the brake disc shield. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 6635 Brake Rotor/Disc: Service and Repair Rear Brake Disc Removal 1. NOTE: When removing the rear brake disc in this procedure it is not necessary to disconnect the hydraulic lines. Remove the rear disc brake caliper. 2. NOTE: If the rear brake disc binds on the rear parking brake shoe and linings, remove the adjustment hole access plug and contract the parking brake shoe and lining. Remove the rear brake disc. 3. CAUTION: Use a hub-mount brake lathe if necessary to machine the rear brake disc. Measure the rear brake disc, and resurface as necessary. Install a new rear brake disc if beyond specification. Installation 1. Follow the removal procedure in reverse order. Brake Disc Shield Removal 1. Remove the rear wheel disc brake adapter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 6636 2. Remove the rear wheel disc brake shield. 1 Drill out the rivet. 2 Remove the rear wheel disc brake shield. Installation 1. NOTE: Because the rear wheel disc brake shield is held in position by the four rear wheel disc brake adapter bolts, a new rivet is not required. Seal the rivet hole with Clear Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A, and install the rear wheel disc brake shield. 2. Install the rear wheel disc brake adapter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Brake Drum: Specifications .............................................................................................................................................................. .............................................. Max Drum Diameter Rear ..................................................................................................................................................... ......................................... 11.0866 inch (281.60mm) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications Caliper bleeder screw, rear 15 ft.lb Caliper bleeder screw, front 15 ft.lb Master cylinder bleeder screw 70-159 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding Brake Bleeding: Service and Repair Brake Caliper Bleeding 1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was disconnected. Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 4. Tighten the disc brake caliper bleeder screw. Refer to Specifications. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6647 Brake Bleeding: Service and Repair Brake System 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 eyes 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 brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 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. NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 4. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 5. Tighten the RH rear bleeder screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6648 6. Repeat Steps 2, 3, 4 and 5 for the LH rear bleeder screw. 7. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 8. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 9. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH front disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 10. Tighten the RH front disc brake caliper bleeder screw. 11. Repeat Steps 7, 8, 9 and 10 for the LH front disc brake caliper bleeder screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6649 Brake Bleeding: Service and Repair Brake System Pressure Bleeding 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. 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. Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose to the fitting on the adapter. 3. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Open the valve on the bleeder tank. 5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw and remove the rubber hose. 6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the RH front disc brake caliper bleeder screw ending with the LH front disc brake caliper bleeder screw. 7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6650 Brake Bleeding: Service and Repair Four Wheel ABS Hydraulic Control Unit (HCU) NOTE: This procedure only needs to be performed if the 4-wheel anti-lock brake (4WABS) hydraulic control unit (HCU) has been installed new. 1. Connect the scan tool DCL cable adapter into the vehicle data link connector (DLC) under the dash, and follow the scan tool instructions for bleeding. 2. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master cylinder reservoir with the specified brake fluid. 3. Connect a clear drain tube to the RH rear bleeder screw and the other end in a container partially filled with recommended brake fluid. 4. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 5. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 6. Tighten the bleeder screw. 7. Repeat Steps 3 - 6 for the LH rear bleeder screw, the RH front bleeder screw and the LH front bleeder screw, in that order. 8. Repeat the conventional bleed procedure as outlined in Steps 3 - 7. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6651 Brake Bleeding: Service and Repair Master Cylinder Priming - In-Vehicle or Bench Special Tools WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes 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 brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 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. NOTE: When any part of the hydraulic system has been disconnected for repair or installation, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: When the brake master cylinder has been installed new or the system has been emptied or partially emptied, it must be primed to prevent air from entering the system. 1. For in-vehicle priming, disconnect the brake lines from the brake master cylinder. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6652 2. For bench priming, mount the brake master cylinder in a vise. 3. Install short brake tubes with the ends bent into the brake master cylinder reservoir. ^ Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. 4. For a new brake master cylinder, remove the cruise switch. 5. Fill the cruise switch with the specified brake fluid. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6653 6. Install the cruise switch. 7. Slowly depress the primary piston or, for in-vehicle priming, have an assistant slowly pump the brake pedal until clear brake fluid flows from both brake tubes with no air bubbles. 8. If necessary, install the brake master cylinder into the vehicle. 9. Remove the short brake tubes and install the master cylinder outlet tubes. 10. Loosen a brake outlet tube at the 4WABS hydraulic control unit (HCU). 11. NOTE: Refill the brake master cylinder reservoir as necessary. Have an assistant depress and hold the brake pedal. 12. Tighten the outlet tube fitting at the HCU. 13. Repeat the above three steps until no air bubbles are seen in the expelled brake fluid. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Caliper Bleeding > Page 6654 14. Repeat the above four steps for the remaining master cylinder outlet tube. 15. Connect one end of a flexible tube to the master cylinder bleeder screw. Submerge the other end in a container partially filled with the specified brake fluid. 16. Have an assistant pump and then hold firm pressure on the brake pedal. 17. NOTE: Refill the brake master cylinder reservoir as necessary. Loosen the master cylinder bleeder screw until brake fluid flows out of the drain tube. 18. Tighten the master cylinder bleeder screw. 19. Repeat the above three steps until there are no air bubbles in the expelled brake fluid. 20. Bleed the brake system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Page 6655 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Front Brake Caliper: Specifications Front disc brake caliper anchor plate bolts 72 - 97 ft.lb Disc brake caliper bolts 21 - 26 ft.lb Disc brake caliper bleeder screw 13-17 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Front > Page 6660 Brake Caliper: Specifications Brake caliper bolts 20 ft.lb Caliper flow bolt 23-29 ft.lb Disc brake caliper bleeder screw 13-17 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Brake Caliper: Service and Repair Front Caliper Removal and Installation Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle, This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes 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: 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. Disconnect the front brake hose. 1 Remove the front brake hose bolt. 2 Disconnect the front brake hose. 3 Remove and discard the copper washers. Plug the front brake hose. 4. Remove the disc brake caliper. 1 Remove the disc brake caliper bolts. 2 Lift the disc brake caliper off the front disc brake caliper anchor plate. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6663 5. Inspect the disc brake caliper for leaks. ^ If leaks are found, disassembly is required. Installation 1. Install the disc brake caliper. 1 Install the disc brake caliper. 2 Install the disc brake caliper bolts. 2. Install the front brake hose. ^ Use new copper washers; connect the front brake hose. ^ Install the front brake hose bolt. 3. Bleed the disc brake caliper. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the wheel and tire assembly. 5. Inspect the brake system operation. Caliper Disassembly and Assembly Disassembly 1. Remove the disc brake caliper. 2. Drain remaining brake fluid from the disc brake caliper. 3. Secure the disc brake caliper in a vise. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6664 4. Remove the caliper pistons. 1 Place a block of wood between the caliper bridge and the caliper pistons. 2 Apply low air pressure to the fluid port in the disc brake caliper. 3 Force out the caliper piston to the block of wood. 4 Remove the block of wood and the caliper pistons. 5. Remove and discard the piston seals and boots. 6. NOTE: Do not hone the caliper bores. Pistons are not available for honed caliper bores. If the caliper bores are excessively scored or corroded, install a new disc brake caliper. Assembly 1. CAUTION: Never reuse piston seals or dust boots. NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. Lubricate the piston boot, caliper piston, piston seal, and cylinder bores with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6665 2. Install the caliper pistons. 1 Install the piston seal. 2 Install the piston boot. 3 CAUTION: Be careful not to damage or dislodge the piston seal. Insert the caliper piston. 4 Press the caliper piston into the caliper bore, being careful not to cock the caliper piston. 3. Install the disc brake caliper. Brake Caliper Anchor Plate Removal 1. NOTE: AWD and 4x4 shown, 4x2 similar. Remove the pads. 2. Remove the front disc brake caliper anchor plate. 1 Remove the two front disc brake caliper anchor plate bolts. 2 Remove the front disc brake caliper anchor plate. Installation 1. Install the front disc brake caliper anchor plate. 1 Position the front disc brake caliper anchor plate. 2 Install the front disc brake caliper anchor plate bolts. 2. Install the pads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6666 Brake Caliper: Service and Repair Rear Caliper Removal and Installation Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes 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: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Disconnect the brake hose. 1 Remove bolt. 2 Disconnect the rear wheel brake hose. 3 Remove the copper washers and plug the brake hose. 4. CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The guide pins are meant to be sealed for life and are not repairable. Use Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A for re-lubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in contamination and accelerated corrosion or wear of the caliper slide pin mechanism. Remove the rear disc brake caliper. 1 Remove the brake caliper bolts. 2 Lift the rear disc brake caliper off the rear disc brake caliper anchor plate. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6667 5. Inspect the rear disc brake caliper for leaks. ^ If leaks are found, disassembly is required. Installation 1. CAUTION: To prevent interference with rear disc brake caliper operation, install only the correct caliper bolt. NOTE: Make sure the stainless steel shoe slippers are correctly positioned. Install new slippers if worn or damaged. NOTE: When installed, the locator notch on the brake pads will be located at the upper end of the rear disc brake caliper. Install the rear disc brake caliper. 2. Install the rear wheel brake hose. ^ Connect the brake hose and install the caliper flow bolt. ^ Use new copper washers. 3. Bleed the disc brake caliper. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the wheel and tire assembly. 5. Verify correct brake operation. Caliper Disassembly and Assembly Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6668 Disassembly 1. Remove the rear disc brake caliper. 2. Drain the remaining brake fluid from the rear disc brake caliper. 3. Secure the rear disc brake caliper in a vise. 4. Remove the rear disc brake piston. 1 Place a block of wood between the caliper bridge and the rear disc brake piston. 2 Apply low air pressure to the fluid port in the rear disc brake caliper. 3 Force the rear disc brake piston out to the block of wood. 4 Remove the block of wood and the rear disc brake piston. 5. NOTE: Do not hone the cylinder bore. Pistons are not available for honed cylinder bores. If the rear disc brake caliper cylinder bore/piston is excessively scored or corroded, install a new rear disc brake caliper. Remove and discard the piston seal and dust boot. Assembly CAUTION: Never reuse the piston seal or dust boot. NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6669 1. Lubricate the following with High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. ^ cylinder bore ^ piston seal ^ rear disc brake piston ^ dust boot 2. Install the piston seal. 3. Install the dust boot. 4. CAUTION: Be careful not to damage or dislodge the piston seal. Install the rear disc brake piston. 5. Install the rear disc brake caliper. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6670 Rear Disc Brake Adapter Removal 1. Disconnect the rear parking brake cable guide. 2. Remove the axle shaft. 3. Remove the bolts and the rear wheel disc brake adapter. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Brake Fluid High Performance DOT 3 Dot 4 may be used if Dot 3 is not available. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 6674 Brake Fluid: 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 eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Clean, fresh Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A is the only brake fluid that should be used in Ford vehicles. ^ Do not reuse brake fluid drained or bled from the system. ^ Do not use brake fluid that has been stored in an open container. ^ Do not use contaminated brake fluid. ^ Do not mix different types of brake fluid. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 6678 Brake Fluid Level Sensor/Switch: Description and Operation The brake master cylinder fluid level warning switch is an integral part of the brake master cylinder reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the brake master cylinder reservoir. When the brake fluid in the brake master cylinder reservoir gets to a predetermined level, the floating magnet actuates the reed switch, causing the red brake warning indicator to illuminate. Loss of brake fluid will cause this system to activate. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Specifications Brake Fluid Pressure Sensor/Switch: Specifications Brake pressure switch 11-14 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications Brake Hose/Line: Specifications Front brake hose bolt 23-29 ft.lb Front brake hose bracket 10-12 ft.lb Front brake tube 12-14 ft.lb Rear brake hose to caliper bolt 23 - 29 ft.lb Brake hose bracket to rear axle bolt 10 - 12 ft.lb Rear brake tube fitting 12 - 14 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 6685 Brake Hose/Line: Service and Repair CAUTION: Never use copper tubing. It is subject to fatigue, cracking and corrosion, which could result in brake tube failure. If a section of brake tube is damaged, the entire section must be installed new with a tube of the same type, size, shape and length. When installing hydraulic brake tubing, hoses, or connectors, tighten all connections to specifications. After installation, bleed the brake system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications Brake Proportioning/Combination Valve: Specifications Brake pressure control valve 10 - 16 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Brake line to (EHCU) nuts (M10-1) 12-16 ft.lb Brake line to (EHCU) nuts (M12-1) 15-18 ft.lb Electronic hydraulic control unit bolts 9-13 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6692 Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6693 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Disconnect the electrical connector by lifting up on the release tab. 3. Disconnect the brake lines from the hydraulic control unit (HCU). 4. Remove the HCU. 1 Remove the bolts. 2 Remove the HCU. 5. Remove the anti-lock brake control module. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6694 1. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes 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: 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. CAUTION: After the HCU is installed, it is necessary to bleed the hydraulic brake system. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Brake Master Cylinder Brake Master Cylinder: Specifications Brake master cylinder nut 14 - 19 ft.lb Master cylinder brake tube nuts 12 - 14 ft.lb Master cylinder bleeder screw 6 - 13 ft.lb Brake master cylinder tube fitting, front 11 - 14 ft.lb Brake master cylinder tube fitting, rear 11 - 14 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Brake Master Cylinder > Page 6699 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 6700 Brake Master Cylinder: Description and Operation The brake master cylinder is a dual-piston type. The brake master cylinder is assisted by a power brake booster. The following conditions are considered normal and not indications that the brake master cylinder is in need of repair or replacement: ^ Low brake fluid level detected without signs of leakage. This condition is caused by displacement of brake fluid from the brake master cylinder reservoir into the disc brake calipers/rear disc brake calipers to compensate for normal brake wear. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. ^ A momentary or slight squirt of brake fluid inside the brake master cylinder reservoir upon application of the brake pedal. ^ A trace of brake fluid found on the outside of the power brake booster below the brake master cylinder mounting flange. This condition results from the lubricating action of the brake master cylinder wiping seal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > General Procedures Brake Master Cylinder: Testing and Inspection General Procedures Normal Conditions The following conditions are considered normal and are not indications that the brake master cylinder is in need of service. Condition 1: During normal operation of the brake master cylinder, the fluid level in the brake master cylinder reservoir will rise during brake application and fall during release. The net fluid level (after brake application and release) will remain unchanged. Condition 2: A trace of brake fluid will exist 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. Refer to the Symptom Chart at Brakes and Traction Control/Testing and Inspection for abnormal condition diagnosis. Bypass Condition Test 1. Disconnect the brake lines at the brake master cylinder. 2. Plug the outlet ports of the brake master cylinder. 3. Apply the brakes. If brake pedal height cannot be maintained, the brake master cylinder has an internal leak and must be rebuilt or installed new. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > General Procedures > Page 6703 Brake Master Cylinder: Testing and Inspection Compensator Port Check The purpose of the compensator ports in the brake master cylinder is to supply any additional brake fluid required by the system due to brake pad wear and to allow brake fluid returning from the brake lines to the brake master cylinder to enter the brake master cylinder reservoir. The returning brake fluid will cause a slight turbulence in the brake master cylinder reservoir. Turbulence seen in the brake master cylinder reservoir upon release of the brake pedal is normal and shows that the compensating ports are not plugged. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Page 6704 Brake Master Cylinder: Adjustments Master Cylinder Push Rod Adjustment 1. Remove the brake master cylinder. 2. CAUTION: Do not apply the brake pedal with the master cylinder removed from the booster. Adjust the power brake booster to brake master cylinder push rod, vacuum applied. 1 Measure the power brake booster to brake master cylinder push rod. 2 If necessary, adjust the screw to the correct length. 3. Install the brake master cylinder. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation Brake Master Cylinder: Service and Repair Removal and Installation Removal WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. 1. Disconnect the brake fluid level warning switch. 2. On cruise control equipped vehicles, disconnect the brake pressure switch. 3. Disconnect the two brake lines, and plug the lines and the brake master cylinder ports. 4. On vehicles with 4.0L engine, remove the wiring retainer clip from the master cylinder. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation > Page 6707 5. Remove the brake master cylinder. 1 Remove the nuts. 2 Remove the brake master cylinder. Installation 1. Follow the removal procedure in reverse order. ^ Bleed the brake master cylinder before installation. ^ Bleed the brake system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation > Page 6708 Brake Master Cylinder: Service and Repair Brake Fluid Reservoir Removal WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. 1. Disconnect the brake master cylinder fluid level warning switch. 2. Use a suitable suction device to drain the brake master cylinder reservoir. 3. Carefully pry up on the brake master cylinder reservoir to remove. Installation 1. NOTE: Whenever installing a new brake master cylinder reservoir, install new grommets. Install the brake master cylinder reservoir. 1 Lubricate the two grommets with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A, and insert the grommets in the brake master cylinder. 2 Press the brake master cylinder reservoir into the grommets until it snaps. 3 Connect the brake master cylinder fluid level warning switch. 4 Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Specifications Parking Brake Cable: Specifications Torque Specifications Parking brake cable and conduit clip bolt ..................................................................................................................................... 15-20 Nm (11-14 lb.ft) Parking brake cable retainer clip bolt .............................................................................................................................................. 6-8 Nm (54-70 in.lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front Parking Brake Cable: Service and Repair Cable and Conduit - Front Removal 1. Remove the parking brake control. 2. Disconnect the front parking brake cable from the parking brake control. 3. Remove the front parking brake cable and conduit housing. 1 Compress the front parking brake cable and conduit-to-parking brake control clip. 2 Remove the front parking brake cable and conduit housing. Installation 1. Follow the removal procedure in reverse order. ^ Make sure cable is routed through loop on take up spool. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 6715 Parking Brake Cable: Service and Repair Cable and Conduit - Rear Removal 1. NOTE: Make sure the parking brake control is fully released. Relieve the tension on the parking brake system. 1 Pull the front parking brake cable and conduit. 2 Insert a 4 mm (5/32 inch) drill bit or equivalent retainer. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 3. Remove the tire and wheel assembly. 4. NOTE: Disconnect the parking brake intermediate cable from the locating hole end of the connector. Disconnect the parking brake intermediate cable from the LH parking brake rear cable and conduit. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 6716 5. Separate the RH parking brake rear cable and conduit from the LH parking brake rear cable and conduit at the parking brake cable equalizer. 6. Remove the RH parking brake rear cable and conduit from the parking brake cable bracket 1 Compress the parking brake cable clip. 2 Remove the RH parking brake rear cable and conduit from the parking brake cable bracket. 7. Remove the RH parking brake rear cable and conduit to LH parking brake rear cable and conduit clip. 8. Remove the RH parking brake rear cable and conduit from the rear parking brake cable retainer. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 6717 9. Remove the RH parking brake rear cable and conduit to the RH hydraulic brake line clip. 10. Remove the parking brake cable retainer clip. 1 Remove the parking brake cable retainer clip bolt. 2 Remove the parking brake cable retainer clip. 11. Unclip the parking brake rear cable and conduit from the brake line clip on top of the rear axle housing. 12. Compress the retainer and release the parking brake rear cable and conduit from the rear disc brake caliper anchor plate. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 6718 13. Unclip the parking brake rear cable and conduit from the parking brake lever. Installation 1. Clip the parking brake rear cable and conduit to the parking brake lever. 2. Connect the parking brake rear cable and conduit to the rear disc brake caliper anchor plate. 3. Clip the parking brake rear cable and conduit to the brake line clip on top of the rear axle housing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 6719 4. Install the parking brake cable retainer clip. 1 Position the parking brake cable retainer clip. 2 Install the parking brake cable retainer clip bolt. 5. Install the RH parking brake rear cable and conduit to the RH hydraulic brake line clip. 6. Hook the RH parking brake rear cable and conduit to the rear parking brake cable retainer. 7. Install the RH parking brake rear cable and conduit to the LH parking brake rear cable and conduit clip. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 6720 8. Connect the RH parking brake rear cable and conduit to the parking brake cable bracket. 1 Install the RH parking brake rear cable and conduit to the parking brake cable bracket. 2 Push the RH parking brake rear cable and conduit into the parking brake cable bracket until the parking brake cable and conduit clip is seated. 9. Connect the RH parking brake rear cable and conduit to the LH parking brake rear cable and conduit at the parking brake cable equalizer. 10. Connect the parking brake intermediate cable to the LH parking brake rear cable and conduit. 11. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the front wheel and tire assemblies. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 6721 12. Apply tension to the parking brake system. 1 Pull down on the front parking brake cable and conduit. 2 Remove the retainer. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications Parking Brake Control: Specifications Torque Specifications Parking brake control bolts .............................................................................. ................................................................................. 17-23 Nm (13-17 lb.ft) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 6725 Parking Brake Control: Service and Repair Removal 1. NOTE: Make sure the parking brake control is fully released. Relieve the tension on the parking brake system. 1 Pull down on the parking brake intermediate cable. 2 Insert a 4 mm (5/32 inch) drill bit or equivalent retainer in the parking brake control. 2. Remove the LH front fender apron. 3. Remove the front parking brake cable and conduit from the retainer clip. 1 Remove the front parking brake cable and conduit retainer clip bolt. 2 Remove the front parking brake cable and conduit retainer clip. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 6726 4. NOTE: Disconnect the front parking brake cable and conduit at the locating hole end of the connector. Disconnect the front parking brake cable and conduit from the parking brake intermediate cable. 5. Remove the front parking brake cable and conduit from the bracket. 1 Compress the retainer from the front parking brake cable and conduit from the bracket. 2 Remove the front parking brake cable and conduit from the bracket. 6. Remove the parking brake release mounting bolts. 7. Remove the parking brake control and front parking brake cable and conduit. 1 Disconnect the parking brake signal switch electrical connector. 2 Remove the three parking brake control bolts. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 6727 1. Follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch > Component Information > Specifications Parking Brake Release Switch: Specifications Parking brake remote release to instrument panel ......................................................................................................................... 2.1-2.9 Nm (19-25 ft. lbs) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications Parking Brake Shoe: Specifications Parking brake shoes and lining minimum thickness 0.04 ft Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications > Page 6734 Parking Brake Shoe: Service and Repair Special Service Tool(s) Removal 1. NOTE: Make sure the parking brake control is fully released. Relieve the tension on the parking brake system. 1 Pull the front parking brake cable and conduit. 2 Insert a 4 mm (5/32 inch) drill bit or equivalent retainer. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 3. Remove the tire and wheel assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications > Page 6735 4. Remove the rear brake disc. 5. Remove the brake shoe retracting spring. 6. Remove the brake shoe adjusting screw spring. 7. Remove the brake adjuster screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications > Page 6736 8. Remove the rear brake shoe hold-down springs. 9. Remove the rear brake shoes and linings along with the inboard brake shoe retracting spring. 10. Inspect the components for excessive wear or damage and install new as required. Installation 1. NOTE: Lubricate the brake shoe contact point before installation of rear shoes using Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford Specification ESE-M1C171-A. Install the rear brake shoes and linings along with the inboard brake shoe retracting spring. 2. Install the brake shoe hold-down springs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications > Page 6737 3. Install the brake adjuster screw. 4. Install the brake shoe adjusting screw spring. 5. Install the outboard brake shoe retracting spring. 6. Use Brake Adjusting Gauge to measure the inside diameter of the drum portion of the rear brake disc. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications > Page 6738 7. Use Brake Adjusting Gauge to set the rear brake shoe and lining diameter to 0.5 mm (0.020 inch) less than the inside diameter of the drum portion of the rear brake disc. 8. Install the rear brake disc. 9. WARNING: Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal to metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and come off while the vehicle is in motion, causing loss of control. Clean the wheel hub mounting surface. 10. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the wheel and tire assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications > Page 6739 11. Apply tension to the parking brake cable system. 1 Hold the front parking brake cable and conduit taut. 2 Remove the retainer from the parking brake control. 12. Check the operation of the parking brake. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications > Page 6740 Special Tools Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications Power brake booster push rod length 0.99 - 1.01 in Power brake booster nuts 15 - 20 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 6745 Vacuum Brake Booster: Description and Operation The power brake booster: ^ is a dual diaphragm, vacuum assisted power brake booster. ^ is located on the LH side of the bulkhead in the engine compartment, between the brake pedal and brake master cylinder. ^ is divided into separate chambers by the diaphragm. ^ will not operate if vacuum is restricted or if any of the vacuum related power brake components fail. ^ is installed as an assembly. If the power assist fails, the brake system will continue to operate with increased brake pedal effort. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Brake Booster - Operational Check Vacuum Brake Booster: Testing and Inspection Brake Booster - Operational Check 1. Check the hydraulic brake system for leaks or insufficient fluid. 2. With the transmission in NEUTRAL, stop the engine and apply the parking brake control. Apply the brake pedal several times to exhaust all vacuum in the system. 3. Apply the brake pedal and hold it in the applied position. Start the engine. If the vacuum system is operating, the brake pedal will tend to move downward under constant foot pressure. If no motion is felt, the power brake booster system is not functioning. Continue the test with the following steps. 4. Remove the vacuum booster hose from check valve connection. Manifold vacuum must be available at the check valve end of the vacuum booster hose with the engine at idle speed and the transmission in NEUTRAL. If the manifold vacuum is available to the power brake booster, connect the vacuum booster hose to the power brake booster check valve and repeat Steps 2 and 3 above. 5. Check and if no downward movement of the brake pedal is felt, install a new power brake booster. 6. Operate the engine a minimum of 10 seconds at fast idle. Stop the engine, and let the vehicle stand for 10 minutes. Then apply the brake pedal with approximately 89 Nm (20 lbs.) of force. The brake pedal feel should be the same as that noted with the engine operating. If the brake pedal feels hard (no power assist), install a new check valve and retest. If the brake pedal feels spongy, bleed the hydraulic system to remove air. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Brake Booster - Operational Check > Page 6748 Vacuum Brake Booster: Testing and Inspection Vacuum Connection Checks Inspect all hoses and connections. All unused vacuum connectors should be capped. Hoses and their connections should be correctly secured and in good condition with no holes, soft or collapsed areas. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Page 6749 Vacuum Brake Booster: Service and Repair Removal 1. Remove the brake master cylinder. 2. Disconnect the power brake booster hose. 1 Compress the clamp. 2 Disconnect the power brake booster hose. 3. Disconnect the brake pedal to power brake booster push rod. 1 Remove the self-locking pin. 2 Remove the stoplight switch and the brake booster push rod from the brake pedal pin. 3 Remove the brake booster push rod bushing. 4. Remove the bulkhead sound insulator. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Page 6750 5. NOTE: Support the power brake booster. Remove the power brake booster. 1 Remove the nuts. 2 Remove the power brake booster. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 The power brake booster check valve: ^ is located on the front of the power brake booster. ^ is positioned between the power brake booster and the power brake booster hose. ^ closes when the engine is turned off. ^ in the closed position, traps engine vacuum in the power brake booster. ^ retains vacuum to provide several power assisted brake applications with the engine off. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Description and Operation > Page 6754 Vacuum Brake Booster Check Valve: Testing and Inspection 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. To test the function of the power brake booster check valve: ^ Start and run the engine for at least 10 seconds. ^ Operate the brake pedal to check for power assist. ^ Disconnect the vacuum booster hose from the power brake booster. Do not remove the power brake booster check valve from the power brake booster. ^ 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications Anti-lock brake control module bolts 1.8 - 1.9 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 6759 Electronic Brake Control Module: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 6760 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 6761 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 6762 Electronic Brake Control Module: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is part of, please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 6763 Electronic Brake Control Module: Service and Repair Removal 1. CAUTION: Prior to removal of the module, it is necessary to upload module configuration information to the scan tool. This information needs to be downloaded into the new module once installed. Disconnect the battery ground cable. 2. Remove the hydraulic control unit bolts. 3. Disconnect the anti-lock brake control module electrical connectors. 4. Remove the anti-lock brake control module. 1 Remove the bolts. 2 Remove the control module. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 6764 1. CAUTION: Once the new module is installed, it is necessary to download the module configuration information from the scan tool into the module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 6769 Brake Fluid Level Sensor/Switch: Description and Operation The brake master cylinder fluid level warning switch is an integral part of the brake master cylinder reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the brake master cylinder reservoir. When the brake fluid in the brake master cylinder reservoir gets to a predetermined level, the floating magnet actuates the reed switch, causing the red brake warning indicator to illuminate. Loss of brake fluid will cause this system to activate. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Specifications Brake Fluid Pressure Sensor/Switch: Specifications Brake pressure switch 11-14 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Differential Speed Sensor > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Specifications Parking Brake Release Switch: Specifications Parking brake remote release to instrument panel ......................................................................................................................... 2.1-2.9 Nm (19-25 ft. lbs) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Front anti-lock brake sensor bolt (4x2) 71 - 88 ft.lb Front anti-lock brake sensor wire retaining bolt (4x4) 62 - 80 ft.lb Front anti-lock brake sensor bolt (4x4) 62 - 80 ft.lb Rear anti-lock brake sensor bolt 20 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left Front Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left Front > Page 6784 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front Wheel Speed Sensor: Service and Repair Sensor, Front Removal 1. Raise and support the vehicle. 2. Disconnect the front anti-lock brake sensor wire from the vehicle frame. 1 Disconnect the electrical connector. 2 Unclip the front anti-lock brake sensor wire from the vehicle frame. 3. Remove the front anti-lock brake sensor. 1 Remove the bolt. 2 Remove the front ant1 -lock brake sensor. Installation 1. NOTE: Plug the sensor mount opening and thoroughly clean the mounting surface. Apply High Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A meeting Ford specification ESA-M1Cl98-A. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 6787 Wheel Speed Sensor: Service and Repair Sensor, Rear Removal 1. Raise and support vehicle. 2. NOTE: Clean off dirt and debris that may have collected around the rear anti-lock brake sensor before removal. Remove the rear anti-lock brake sensor. 1 Disconnect the rear anti-lock brake sensor electrical connector. 2 Remove the bolt. 3 Remove the rear anti-lock brake sensor. Installation 1. NOTE: Thoroughly clean the mounting surface. NOTE: Inspect the anti-lock brake sensor O-ring for damage; lightly lubricate the O-ring with High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. 2. Prove out the air bag system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 6798 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 6799 4. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. Installation WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 6800 WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Note: Use a new ignition switch lock cylinder. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. 2. Prove out the air bag system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 6804 Neutral Safety Switch: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 6809 Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 6810 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 6811 Starter Relay: Service Precautions WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 6812 Starter Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 6813 Starter Relay: Service and Repair REMOVAL WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE. 1. Disconnect the battery ground cable. 2. Disconnect the starter motor solenoid relay switch wiring. 1 Remove the protective cover. 2 Disconnect the push-on electrical connector. 3 Remove the nuts. 4 Remove the cable. 3. Remove the starter motor solenoid relay switch. 1 Remove the engine sensor/generator wires. 2 Remove the bolts and ground wire. 3 Remove the starter motor solenoid relay switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications Battery Cable: Specifications Battery Cable Clamp Bolts 7-10 Nm Battery Cable Bolts 7-10 Nm Battery Ground Cable To Frame Bolt 11-13 Nm Battery Ground Cable To Radiator Support Nut 11-13 Nm Battery Ground Cable To Starter Motor Stud Nut 23-32 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications > Page 6818 Battery Cable: Service and Repair REMOVAL 1. Disconnect the battery cables. 1 Disconnect the battery ground cable. 2 Disconnect the battery to starter relay cable. 2. Remove the three battery cable wire harness pushpins. 3. Remove the nut and the chassis ground cable. 4. Raise and support the vehicle; refer to Maintenance/Service and Repair. 5. Remove the bolt, the frame ground cable, and the bracket. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications > Page 6819 6. Remove the bolt from the battery cable bracket. 7. Remove the battery ground cable nut from the starter motor stud and remove the battery ground cable. 8. Remove the starter motor wiring harness. 1 Remove the push-on electrical connector. 2 Remove the starter motor wiring harness to starter motor nut and wire. ^ Remove battery cable wiring harness. INSTALLATION 1. Install the starter motor wiring harness. 1 Install the starter motor wiring harness to starter motor wire and nut. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications > Page 6820 2 Install the push-on electrical connector. 2. Install the battery ground cable to the starter motor stud and install the nut. 3. Install the battery cable bracket and the bolt. 4. Position the frame ground cable, bracket and install the bolt. 5. Lower the vehicle. 6. Install the chassis ground cable and the nut. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications > Page 6821 7. Install the three battery cable wire harness pushpins. 8. Connect the battery to starter relay cable and then connect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Pulley > Component Information > Service and Repair Alternator Pulley: Service and Repair REMOVAL 1. Disconnect the battery. For additional information, refer to Battery Service and Repair. 2. Remove the Generator (GEN). For additional information, refer to Generator Service and Repair. 3. Remove the (A) nut and the (B) generator pulley. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Specifications Voltage Regulator: Specifications Voltage Regulator/Brush Holder Screws 2.3-3.4 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Specifications > Page 6830 Voltage Regulator: Service and Repair REMOVAL 1. Remove the generator. For additional information, refer to Generator Service and Repair. 2. Remove the voltage regulator/brush holder assembly. 1 Remove the screws. 2 Remove the voltage regulator/brush holder assembly. INSTALLATION 1. Install the voltage regulator/brush holder assembly. 1 Depress the brushes and insert a wire to hold brushes during installation. 2 Install the voltage regulator/brush holder assembly. 3 Install the screws and remove the wire. 2. Install the generator. For additional information, refer to Generator Service and Repair. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. 2. Prove out the air bag system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 6840 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 6841 4. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. Installation WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 6842 WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Note: Use a new ignition switch lock cylinder. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. 2. Prove out the air bag system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 6846 Neutral Safety Switch: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component Information > Locations > Page 6851 Starter Drive/Bendix: Testing and Inspection STARTER DRIVE AND FLYWHEEL RING GEAR INSPECTION 1. Remove the starter motor; refer to Starter Motor Service and Repair. 2. Check the wear patterns on the starter drive gear and the flywheel ring gear. If the wear pattern is normal, install the starter motor; refer to Starter Motor Service and Repair. 3. If the starter drive gear and the flywheel ring gear are not fully meshing and both of the gears are scored or damaged, replace the starter motor; refer to Starter Motor Service and Repair. If necessary, replace the flywheel; refer to Engine. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 6855 Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 6856 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 6857 Starter Relay: Service Precautions WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 6858 Starter Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 6859 Starter Relay: Service and Repair REMOVAL WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE. 1. Disconnect the battery ground cable. 2. Disconnect the starter motor solenoid relay switch wiring. 1 Remove the protective cover. 2 Disconnect the push-on electrical connector. 3 Remove the nuts. 4 Remove the cable. 3. Remove the starter motor solenoid relay switch. 1 Remove the engine sensor/generator wires. 2 Remove the bolts and ground wire. 3 Remove the starter motor solenoid relay switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications Starter Solenoid: Specifications Solenoid Bolts 5-10 Nm Starter Solenoid B-Terminal Nut 10-15 Nm Starter Solenoid S-Terminal Nut 5-7 Nm B+ Terminal Nut 9-12 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications > Page 6863 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Auxilirary Relay Box #1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Auxilirary Relay Box #1 > Page 6872 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Auxilirary Relay Box #1 > Page 6873 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Auxilirary Relay Box #1 > Page 6874 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Auxilirary Relay Box #1 > Page 6875 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions Electrical Accessory Panel: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6878 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6879 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6880 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6881 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6882 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6883 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6884 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6885 Electrical Accessory Panel: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6886 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6887 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6888 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6889 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6890 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6891 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 SOHC VIN K SFI (2001)) 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 6900 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 SOHC VIN K SFI (2001)) 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 6901 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 SOHC VIN K SFI (2001)) 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 6902 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 SOHC VIN K SFI (2001)) 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 6903 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 SOHC VIN K SFI (2001)) 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 6904 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 SOHC VIN K SFI (2001)) 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 6905 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 SOHC VIN K SFI (2001)) 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 6906 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 SOHC VIN K SFI (2001)) 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 6907 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 SOHC VIN K SFI (2001)) 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 SOHC VIN K SFI (2001)) 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 6913 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 SOHC VIN K SFI (2001)) 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 6914 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 SOHC VIN K SFI (2001)) 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 6915 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 SOHC VIN K SFI (2001)) 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 6916 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 SOHC VIN K SFI (2001)) 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 6917 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 SOHC VIN K SFI (2001)) 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 6918 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 SOHC VIN K SFI (2001)) 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 6919 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 SOHC VIN K SFI (2001)) 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 6920 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6925 Fuse 1 - 18 Fuse 19 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6926 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6927 Fuse 1 - 10 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6928 Fuse 11 - 31 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6929 Fuse 32 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6930 Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6931 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6932 Relays Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6933 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6934 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6935 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6938 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6939 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6940 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6941 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6942 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6943 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6944 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6945 Fuse: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6946 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6947 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6948 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6949 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6950 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6951 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6954 Fuse 1 - 18 Fuse 19 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6955 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6956 Fuse 1 - 10 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6957 Fuse 11 - 31 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6958 Fuse 32 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6959 Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6960 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6961 Relays Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6962 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6963 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6964 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse Block: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6969 Fuse 1 - 18 Fuse 19 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6970 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6971 Fuse 1 - 10 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6972 Fuse 11 - 31 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6973 Fuse 32 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6974 Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6975 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6976 Relays Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6977 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6978 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6979 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6982 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6983 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6984 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6985 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6986 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6987 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6988 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6989 Fuse Block: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6990 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6991 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6992 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6993 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6994 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6995 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse Block: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6998 Fuse 1 - 18 Fuse 19 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 6999 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7000 Fuse 1 - 10 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7001 Fuse 11 - 31 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7002 Fuse 32 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7003 Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7004 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7005 Relays Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7006 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7007 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7008 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ground Strap > Component Information > Specifications Ground Strap: Specifications Intake Manifold Ground Strap Nut ...................................................................................................................................................... 7-9 Nm (62-80 Lb-In) Battery Ground Cable Screw .............................................................................................................................................................. 7-10 Nm (62-89 Lb-In) Cylinder Head Ground Strap Bolt .............................................................................................................................................. 8.9-12.1 Nm (79-107 Lb-In) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ground Strap > Component Information > Specifications > Page 7012 Ground Strap: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the nut and washer (A) attaching the ground strap (B) to the stud. 3. Remove the fastener from the rear of the right cylinder head and ensure that the mounting surfaces of the studs are free of dirt and corrosion. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ground Strap > Component Information > Specifications > Page 7013 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7024 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7025 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7026 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7027 Multiple Junction Connector: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7028 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7029 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7030 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7031 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7032 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7033 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7034 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7035 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7036 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7037 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7038 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7039 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7040 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7041 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7042 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7043 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7044 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7045 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7046 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7047 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7048 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7049 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7050 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7051 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7052 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7053 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7054 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7055 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7056 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7057 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7058 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Power Distribution Relay: Locations Trailer Tow Park Lamp Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7062 4 Door W/Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7063 2 Door W/Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7064 Power Distribution Relay: Testing and Inspection Trailer Tow Park Lamp Relay Test Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Power Distribution Relay: Locations Trailer Tow Park Lamp Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7075 4 Door W/Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7076 2 Door W/Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7077 Power Distribution Relay: Testing and Inspection Trailer Tow Park Lamp Relay Test Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7082 Fuse 1 - 18 Fuse 19 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7083 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7084 Fuse 1 - 10 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7085 Fuse 11 - 31 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7086 Fuse 32 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7087 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7088 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7089 Relays Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7090 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7091 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7092 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 7095 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 7096 Relay Box: Diagrams Auxiliary Relay Box #2 2 Door W/o Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 7097 4 Door W/Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 7098 2 Door W/Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7101 Fuse 1 - 18 Fuse 19 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7102 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7103 Fuse 1 - 10 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7104 Fuse 11 - 31 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7105 Fuse 32 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7106 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7107 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7108 Relays Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7109 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7110 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7111 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7116 Fuse 1 - 18 Fuse 19 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7117 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7118 Fuse 1 - 10 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7119 Fuse 11 - 31 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7120 Fuse 32 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7121 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7122 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7123 Relays Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7124 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7125 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7126 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 7129 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 7130 Relay Box: Diagrams Auxiliary Relay Box #2 2 Door W/o Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 7131 4 Door W/Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 7132 2 Door W/Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7135 Fuse 1 - 18 Fuse 19 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7136 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7137 Fuse 1 - 10 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7138 Fuse 11 - 31 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7139 Fuse 32 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7140 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7141 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7142 Relays Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7143 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7144 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7145 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips Technical Service Bulletin # 05-18-7 Date: 050922 Electrical - Wiring Soldering/Crimping Service Tips TSB 05-18-7 09/22/05 WIRING - SOLDERING AND CRIMPING REPAIRS - SERVICE TIPS FORD: 2000-2006 Crown Victoria, Focus, Mustang, Taurus 2002-2005 Thunderbird 2005-2006 Five Hundred, Ford GT, Freestyle 2006 Fusion 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion 2000-2006 E-Series, Expedition, Explorer, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2000-2006 F-650, F-750 2006 Low Cab Forward LINCOLN: 2000-2006 LS, Town Car 2006 Zephyr 2000-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 2000-2002 Cougar 2000-2005 Sable 2000-2006 Grand Marquis 2005-2006 Montego 2006 Milan 2000-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 03-11-6 to update the service procedure, vehicle lines and model years. ISSUE Wire harness repairs are supported through the availability of individual components such as: ^ Wire terminals with machine crimped pigtails ^ Hard shell connectors ^ Dual wall heat shrink tubing ^ Complete, loaded, wiring pigtail kits Some of the available tools and service parts that are helpful when performing wiring harness repairs are: ^ Motorcraft Wiring Pigtail Catalog (see website for more information) ^ Rotunda Wire Splice Tool kit 164-R5903 ^ General Wire Terminal Repair Kit (order through Ford Component Sales) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7150 Information on the pigtail and terminal repair kits can also be accessed by technicians via the P15 web site. To access on PTS: ^ Select the year/model of the vehicle on the P15 home page ^ Select the wiring tab ^ Select the link to the pigtail or terminal repair kit at the top right of screen. Additional service information contained in this TSB detailing wire folding, soldering, and crimping techniques may be helpful. ACTION REPAIR VS REPLACEMENT The approved procedure is to repair wiring harnesses with pigtail kits, wire terminals, or hard shell connectors when available. The only exceptions to this procedure are when: ^ The repair cost exceeds the cost to replace the wiring harness ^ There are no component parts released to service the wiring harness RESTRAINTS RELATED WIRING REPAIRS If restraints connectors or wiring circuits are contained in a stand-alone harness, do not repair them; replace the restraints harness unless directed to repair the circuit by a TSB or other Ford Motor Company publication. If restraints connectors or wiring circuits are contained in the main vehicle wiring harnesses (14401, 14A005, etc.), they should be repaired using the solder and heat-shrink repair procedure specified in this TSB. The General Wire Terminal Repair Kit contains gold plated terminated pigtails (with white insulation) and dual wall heat shrink tubing to perform these repairs. Loaded wiring pigtail kits with gold plated terminals are also available in the parts catalog. Disclaimer Service Tips Refer to applicable model year wiring diagrams for circuit information. Twisted Wire Circuits For "Twisted Wire" circuit repair (Figure 1), the twisting must not be disrupted for more than 2" (51 mm) Twist the repaired wires in the same direction and with the same general twist rate as the original wiring. Reapply the shielding on shielded circuits. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7151 Stagger the repairs to minimize harness diameter and maintain harness length (Figure 2). Any leads that are not going to be used need to be sealed with dual wall heat shrink and stowed (Figure 2). Silicone must not be used. Excess wire from the harness can be folded back on itself to maintain the harness length. Reapply any convolute and tape that was removed to make the repair. For 16 AGW and Smaller Diameter Wire Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7152 1. Strip 1-1/2" (37.2 mm) of insulation from Wire # 1 and 3/4" (19.5 mm) of insulation from Wire # 2, taking care not to nick or cut wire strands (Figure 3). Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. 2. Install heat shrink tubing at least 1" (26 mm) away from one of the stripped ends being spliced. Twist wires together. Solder wires together (Figure 4). NOTE USE ROSIN CORE MILDLY ACTIVATED (RMS) SOLDER. DO NOT USE ACID CORE SOLDER FOR WIRE REPAIR. 3. Bend Wire # 1 back in a straight line for sealing (Figure 4). Inspect solder joint bond. NOTE WAIT FOR SOLDER TO COOL BEFORE MOVING WIRES. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7153 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7154 4. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 5. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). For 14 AGW and Larger Diameter Wire (Excluding Restraints Wiring Repairs) 1. Strip 1/4" (6.35 mm) of insulation from pigtail wire end once the wire lengths are sized so repairs can be staggered. Take care not to nick or cut wire strands. Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7155 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7156 NOTE THE STRIP LENGTH WILL VARY DEPENDING ON THE BUTT SPLICE AND WIRE IN HARNESS. LONGER STRIP LENGTHS ARE REQUIRED WHEN THE WIRE NEEDS TO BE FOLDED TO MATE WITH THE BUTT SPLICE. REFER TO FIGURE 10 CHART FOR STRIP LENGTHS AND FOLDING TECHNIQUES. 2. Slide heat shrink tubing onto one (1) of the wire ends to be crimped, must be at least 1" (25.4 mm) away from stripped end (Figure 6). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7157 3. Identify the appropriate crimping chamber of the Rotunda 164-R5901 Pro-Crimper (or equivalent) by matching the wire size on the dies with the wire size stamped on the butt splice (Figure 7). Hold the crimping tool so the identified wire sizes are facing you. Squeeze tool handles together until the ratchet releases, then allow the jaws of the tool to open fully. 4. Center one (1) end of the butt splice on the appropriate crimping chamber. If visible, be sure to place the brazed seam of the butt splice toward the indenter (Figure 8). 5. Hold the butt splice in place and squeeze the tool handles together until the ratchet engages sufficiently to hold the butt splice in position (typically one (1) or two (2) clicks). DO NOT deform the butt splice. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7158 6. Insert stripped wire into the buff splice, making sure the insulation on wire does not enter the butt splice (Figure 8). 7. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool handles to open, then remove crimped butt splice. 8. To crimp the other half of the splice, reposition the un-crimped wire barrel in the same crimping chamber, and repeat Steps 3-8. If splice cannot be turned for crimping the other half, turn the tool around. 9. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. It is acceptable for crimp to be slightly off center, but not off the end of the buff splice (Figure 9-a). b. Wire insulation does not enter butt splice. Wire is flush with or extends slightly beyond end of buff splice (Figure 9-b). c. Wire is visible through inspection hole of splices (Figure 9-c). 10. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 11. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Auxilirary Relay Box #1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Auxilirary Relay Box #1 > Page 7167 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Auxilirary Relay Box #1 > Page 7168 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Auxilirary Relay Box #1 > Page 7169 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Auxilirary Relay Box #1 > Page 7170 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions Electrical Accessory Panel: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7173 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7174 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7175 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7176 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7177 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7178 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7179 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7180 Electrical Accessory Panel: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7181 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7182 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7183 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7184 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7185 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7186 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 SOHC VIN K SFI (2001)) 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 7195 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 SOHC VIN K SFI (2001)) 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 7196 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 SOHC VIN K SFI (2001)) 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 7197 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 SOHC VIN K SFI (2001)) 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 7198 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 SOHC VIN K SFI (2001)) 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 7199 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 SOHC VIN K SFI (2001)) 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 7200 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 SOHC VIN K SFI (2001)) 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 7201 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 SOHC VIN K SFI (2001)) 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 7202 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 SOHC VIN K SFI (2001)) 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 SOHC VIN K SFI (2001)) 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 7208 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 SOHC VIN K SFI (2001)) 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 7209 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 SOHC VIN K SFI (2001)) 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 7210 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 SOHC VIN K SFI (2001)) 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 7211 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 SOHC VIN K SFI (2001)) 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 7212 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 SOHC VIN K SFI (2001)) 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 7213 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 SOHC VIN K SFI (2001)) 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 7214 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 SOHC VIN K SFI (2001)) 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 7215 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7220 Fuse 1 - 18 Fuse 19 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7221 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7222 Fuse 1 - 10 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7223 Fuse 11 - 31 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7224 Fuse 32 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7225 Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7226 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7227 Relays Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7228 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7229 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7230 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7233 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7234 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7235 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7236 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7237 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7238 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7239 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7240 Fuse: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7241 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7242 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7243 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7244 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7245 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7246 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7249 Fuse 1 - 18 Fuse 19 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7250 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7251 Fuse 1 - 10 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7252 Fuse 11 - 31 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7253 Fuse 32 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7254 Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7255 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7256 Relays Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7257 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7258 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7259 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse Block: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7264 Fuse 1 - 18 Fuse 19 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7265 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7266 Fuse 1 - 10 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7267 Fuse 11 - 31 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7268 Fuse 32 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7269 Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7270 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7271 Relays Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7272 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7273 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7274 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7277 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7278 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7279 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7280 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7281 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7282 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7283 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7284 Fuse Block: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7285 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7286 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7287 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7288 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7289 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7290 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Fuse Block: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7293 Fuse 1 - 18 Fuse 19 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7294 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7295 Fuse 1 - 10 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7296 Fuse 11 - 31 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7297 Fuse 32 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7298 Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7299 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7300 Relays Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7301 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7302 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7303 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Ground Strap > Component Information > Specifications Ground Strap: Specifications Intake Manifold Ground Strap Nut ...................................................................................................................................................... 7-9 Nm (62-80 Lb-In) Battery Ground Cable Screw .............................................................................................................................................................. 7-10 Nm (62-89 Lb-In) Cylinder Head Ground Strap Bolt .............................................................................................................................................. 8.9-12.1 Nm (79-107 Lb-In) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Ground Strap > Component Information > Specifications > Page 7307 Ground Strap: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the nut and washer (A) attaching the ground strap (B) to the stud. 3. Remove the fastener from the rear of the right cylinder head and ensure that the mounting surfaces of the studs are free of dirt and corrosion. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Ground Strap > Component Information > Specifications > Page 7308 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7319 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7320 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7321 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7322 Multiple Junction Connector: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7323 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7324 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7325 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7326 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7327 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7328 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7329 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7330 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7331 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7332 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7333 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7334 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7335 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7336 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7337 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7338 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7339 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7340 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7341 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7342 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7343 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7344 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7345 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7346 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7347 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7348 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7349 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7350 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7351 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7352 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C113 > Page 7353 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Power Distribution Relay: Locations Trailer Tow Park Lamp Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7357 4 Door W/Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7358 2 Door W/Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7359 Power Distribution Relay: Testing and Inspection Trailer Tow Park Lamp Relay Test Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Power Distribution Relay: Locations Trailer Tow Park Lamp Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7370 4 Door W/Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7371 2 Door W/Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7372 Power Distribution Relay: Testing and Inspection Trailer Tow Park Lamp Relay Test Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7377 Fuse 1 - 18 Fuse 19 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7378 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7379 Fuse 1 - 10 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7380 Fuse 11 - 31 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7381 Fuse 32 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7382 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7383 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7384 Relays Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7385 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7386 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7387 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 7390 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 7391 Relay Box: Diagrams Auxiliary Relay Box #2 2 Door W/o Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 7392 4 Door W/Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 7393 2 Door W/Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7396 Fuse 1 - 18 Fuse 19 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7397 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7398 Fuse 1 - 10 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7399 Fuse 11 - 31 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7400 Fuse 32 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7401 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7402 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7403 Relays Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7404 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7405 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7406 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7411 Fuse 1 - 18 Fuse 19 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7412 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7413 Fuse 1 - 10 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7414 Fuse 11 - 31 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7415 Fuse 32 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7416 Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7417 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7418 Relays Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7419 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7420 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7421 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 7424 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 7425 Relay Box: Diagrams Auxiliary Relay Box #2 2 Door W/o Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 7426 4 Door W/Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 7427 2 Door W/Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB) Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7430 Fuse 1 - 18 Fuse 19 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7431 Passenger Compartment Fuse Panel / Central Junction Box (CJB) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7432 Fuse 1 - 10 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7433 Fuse 11 - 31 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7434 Fuse 32 - 36 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7435 Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7436 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7437 Relays Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7438 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7439 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7440 Fuses Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips Technical Service Bulletin # 05-18-7 Date: 050922 Electrical - Wiring Soldering/Crimping Service Tips TSB 05-18-7 09/22/05 WIRING - SOLDERING AND CRIMPING REPAIRS - SERVICE TIPS FORD: 2000-2006 Crown Victoria, Focus, Mustang, Taurus 2002-2005 Thunderbird 2005-2006 Five Hundred, Ford GT, Freestyle 2006 Fusion 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion 2000-2006 E-Series, Expedition, Explorer, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2000-2006 F-650, F-750 2006 Low Cab Forward LINCOLN: 2000-2006 LS, Town Car 2006 Zephyr 2000-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 2000-2002 Cougar 2000-2005 Sable 2000-2006 Grand Marquis 2005-2006 Montego 2006 Milan 2000-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 03-11-6 to update the service procedure, vehicle lines and model years. ISSUE Wire harness repairs are supported through the availability of individual components such as: ^ Wire terminals with machine crimped pigtails ^ Hard shell connectors ^ Dual wall heat shrink tubing ^ Complete, loaded, wiring pigtail kits Some of the available tools and service parts that are helpful when performing wiring harness repairs are: ^ Motorcraft Wiring Pigtail Catalog (see website for more information) ^ Rotunda Wire Splice Tool kit 164-R5903 ^ General Wire Terminal Repair Kit (order through Ford Component Sales) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7445 Information on the pigtail and terminal repair kits can also be accessed by technicians via the P15 web site. To access on PTS: ^ Select the year/model of the vehicle on the P15 home page ^ Select the wiring tab ^ Select the link to the pigtail or terminal repair kit at the top right of screen. Additional service information contained in this TSB detailing wire folding, soldering, and crimping techniques may be helpful. ACTION REPAIR VS REPLACEMENT The approved procedure is to repair wiring harnesses with pigtail kits, wire terminals, or hard shell connectors when available. The only exceptions to this procedure are when: ^ The repair cost exceeds the cost to replace the wiring harness ^ There are no component parts released to service the wiring harness RESTRAINTS RELATED WIRING REPAIRS If restraints connectors or wiring circuits are contained in a stand-alone harness, do not repair them; replace the restraints harness unless directed to repair the circuit by a TSB or other Ford Motor Company publication. If restraints connectors or wiring circuits are contained in the main vehicle wiring harnesses (14401, 14A005, etc.), they should be repaired using the solder and heat-shrink repair procedure specified in this TSB. The General Wire Terminal Repair Kit contains gold plated terminated pigtails (with white insulation) and dual wall heat shrink tubing to perform these repairs. Loaded wiring pigtail kits with gold plated terminals are also available in the parts catalog. Disclaimer Service Tips Refer to applicable model year wiring diagrams for circuit information. Twisted Wire Circuits For "Twisted Wire" circuit repair (Figure 1), the twisting must not be disrupted for more than 2" (51 mm) Twist the repaired wires in the same direction and with the same general twist rate as the original wiring. Reapply the shielding on shielded circuits. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7446 Stagger the repairs to minimize harness diameter and maintain harness length (Figure 2). Any leads that are not going to be used need to be sealed with dual wall heat shrink and stowed (Figure 2). Silicone must not be used. Excess wire from the harness can be folded back on itself to maintain the harness length. Reapply any convolute and tape that was removed to make the repair. For 16 AGW and Smaller Diameter Wire Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7447 1. Strip 1-1/2" (37.2 mm) of insulation from Wire # 1 and 3/4" (19.5 mm) of insulation from Wire # 2, taking care not to nick or cut wire strands (Figure 3). Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. 2. Install heat shrink tubing at least 1" (26 mm) away from one of the stripped ends being spliced. Twist wires together. Solder wires together (Figure 4). NOTE USE ROSIN CORE MILDLY ACTIVATED (RMS) SOLDER. DO NOT USE ACID CORE SOLDER FOR WIRE REPAIR. 3. Bend Wire # 1 back in a straight line for sealing (Figure 4). Inspect solder joint bond. NOTE WAIT FOR SOLDER TO COOL BEFORE MOVING WIRES. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7448 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7449 4. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 5. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). For 14 AGW and Larger Diameter Wire (Excluding Restraints Wiring Repairs) 1. Strip 1/4" (6.35 mm) of insulation from pigtail wire end once the wire lengths are sized so repairs can be staggered. Take care not to nick or cut wire strands. Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7450 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7451 NOTE THE STRIP LENGTH WILL VARY DEPENDING ON THE BUTT SPLICE AND WIRE IN HARNESS. LONGER STRIP LENGTHS ARE REQUIRED WHEN THE WIRE NEEDS TO BE FOLDED TO MATE WITH THE BUTT SPLICE. REFER TO FIGURE 10 CHART FOR STRIP LENGTHS AND FOLDING TECHNIQUES. 2. Slide heat shrink tubing onto one (1) of the wire ends to be crimped, must be at least 1" (25.4 mm) away from stripped end (Figure 6). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7452 3. Identify the appropriate crimping chamber of the Rotunda 164-R5901 Pro-Crimper (or equivalent) by matching the wire size on the dies with the wire size stamped on the butt splice (Figure 7). Hold the crimping tool so the identified wire sizes are facing you. Squeeze tool handles together until the ratchet releases, then allow the jaws of the tool to open fully. 4. Center one (1) end of the butt splice on the appropriate crimping chamber. If visible, be sure to place the brazed seam of the butt splice toward the indenter (Figure 8). 5. Hold the butt splice in place and squeeze the tool handles together until the ratchet engages sufficiently to hold the butt splice in position (typically one (1) or two (2) clicks). DO NOT deform the butt splice. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7453 6. Insert stripped wire into the buff splice, making sure the insulation on wire does not enter the butt splice (Figure 8). 7. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool handles to open, then remove crimped butt splice. 8. To crimp the other half of the splice, reposition the un-crimped wire barrel in the same crimping chamber, and repeat Steps 3-8. If splice cannot be turned for crimping the other half, turn the tool around. 9. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. It is acceptable for crimp to be slightly off center, but not off the end of the buff splice (Figure 9-a). b. Wire insulation does not enter butt splice. Wire is flush with or extends slightly beyond end of buff splice (Figure 9-b). c. Wire is visible through inspection hole of splices (Figure 9-c). 10. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 11. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Alignment Procedure Revision Alignment: Technical Service Bulletins Steering/Suspension - Alignment Procedure Revision TSB 04-24-19 12/13/04 REVISED PROCEDURE FOR ADJUSTING ALIGNMENT ON ALL SUSPENSIONS - NEW RIGHT HAND UPPER CONTROL ARM DESIGN FOR TORSION BAR FRONT SUSPENSIONS FORD: 1998-2001 Explorer 1998-2003 Ranger 2000-2003 Explorer Sport 2001-2003 Explorer Sport Trac ISSUE The cam bolt and nut kit that was used for adjusting caster and camber on all torsion bar and coil spring front suspensions has been discontinued. If the caster and camber settings need to be adjusted, a washer must now be installed. The right hand upper control arm design changed from a two piece design to a single piece design during the 2003 model year. The single piece design is now the only version of the upper control arm available for service of prior model year Rangers. ACTION Use the following Camber And Caster Adjustment procedure when either camber or caster need to be adjusted on any suspension, or if only a caster split adjustment is needed on a vehicle equipped with single piece upper control arm. Use the following Caster Split Adjustment - Two Piece Right Hand Upper Control Arm procedure if only a caster split adjustment is needed on a vehicle equipped with a two piece upper control arm. SERVICE PROCEDURE CAMBER AND CASTER ADJUSTMENT NOTE THE UPPER CONTROL ARM-TO-FRAME MOUNTING BOLTS HAVE SET SHIMS THAT MUST BE REPLACED WITH WASHERS TO ALLOW FOR ADJUSTMENT OF THE ARM IN THE FRAME SLOT. THE VEHICLE SHOULD BE SUPPORTED BY THE LOWER CONTROL ARM TO EASE MOVEMENT OF THE UPPER ARM IN THE SLOT. 1. Remove and discard the upper control arm-to-frame nuts and shims (Figure 1). 2. Install new washers (W705040-5900) and nuts (N805480-5427). Tighten the nuts so there is tension, but the upper control arm can be moved for the alignment adjustment. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Alignment Procedure Revision > Page 7459 3. To adjust caster and camber refer to the chart. Adjustments that require moving the front and rear of the upper control arm should be made equally. 4. Torque the upper control arm-to-frame nuts to 98 lb.ft (133 N.m). 5. Check and if necessary adjust the front toe. Refer to the appropriate Workshop Manual for information. CASTER SPLIT ADJUSTMENT - TWO PIECE RIGHT HAND UPPER CONTROL ARM 1. To decrease the right hand caster, loosen the ball joint adjustment nuts (Figure 2) and move the ball joint forward. 2. To increase the right hand caster, loosen the ball joint adjustment nuts and move the ball joint rearward. 3. Torque the ball joint adjustment nuts to 129 lb.ft (175 N.m). 4. Check and if necessary adjust the front toe. Refer to the appropriate Workshop Manual for information. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 3084 07 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 7460 Alignment: Specifications Caster LH 4.2 - 1.0 deg 0 deg. Frame Angle (If vehicle is higher in the rear, add the frame angle to the measured caster. If vehicle is lower in the rear, subtract the frame angle from the measured caster. Compare the total to the specification.) RH 4.2 - 1.0 deg Total/Split -0.7 +/- 0.5 deg Camber LH -0.5 +/- 0.5 deg RH -0.5 +/- 0.5 deg Total/Split 0 +/- 0.7 deg Toe 0.12 +/- 0.25 deg @ Curb Ride Height (positive value is toe-in, negative value is toe-out) Wheel Track 0.02 in Dogtracking 1.18 in maximum (centerline of front tires compared to centerline of rear tires) Clear Vision -2.4 +/- 3.0 deg (negative value is counterclockwise) Front Ride Height New Vehicles With less than 500 miles 4.4 +/- 0.4 in Original Parts 4.0 +/- 0.4 in Replacement Parts 4.4 +/- 0.1 in Rear Ride Height 4 Door Vehicles 5 - 5.8 in 2 Door Vehicles 4.3 - 4.8 in Ball Joint Radial Play Lower Ball Joint Maximum 1/32 in Upper Ball Joint Maximum 1/32 in Vehicle Lean Front Wheel Opening Maximum 0.6 in Side to Side Height Differences Rear Wheel Opening Maximum 0.78 in Torque Specifications Caster Set Jam Nuts 129 ft lb Front Suspension Upper Arm Cam Nuts 98 ft lb Toe Set Jam Nuts 59 ft lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber Alignment: Description and Operation Camber Negative and Positive Camber Negative and Positive Camber Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or negative and has a direct effect on tire wear. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 7463 Alignment: Description and Operation Caster Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the side. The caster specifications will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 7464 Alignment: Description and Operation Dogtracking Dogtracking Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of dogtracking. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 7465 Alignment: Description and Operation Drift/Pull Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep the vehicle going straight. Drift describes what a vehicle with this condition does with hands off the steering wheel. ^ A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead path and require constant steering input in the opposite direction to counteract the effect. ^ Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road camber). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 7466 Alignment: Description and Operation Camber Negative and Positive Camber Negative and Positive Camber Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or negative and has a direct effect on tire wear. Caster Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the side. The caster specifications will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear. Dogtracking Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 7467 Dogtracking Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of dogtracking. Drift/Pull Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep the vehicle going straight. Drift describes what a vehicle with this condition does with hands off the steering wheel. ^ A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead path and require constant steering input in the opposite direction to counteract the effect. ^ Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road camber). General Information Caster and camber are adjusted by means of eccentric cams on the upper control arm mounting bolts. Toe is adjusted by the use of the front wheel spindle tie-rod. Nibble Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road surfaces and observed by the driver as small rotational oscillations of the steering wheel. Poor Groove Feel Poor groove feel is characterized by little or no buildup of turning effort felt in the steering wheel as the wheel is rocked slowly left and right within very small turns around center or straight-ahead (under 20° of steering wheel turn). Efforts may be said to be "flat on center." ^ Under 20° of turn, most of the turning effort that builds up comes from the mesh of gear teeth in the steering gear. In this range, the steering wheel is not yet turned enough to feel the effort from the self-aligning forces at the road wheel or tire patch. ^ In the diagnosis of a readability problem, it is important to understand the difference between wander and poor groove feel. Poor Returnability/Sticky Steering Poor returnability and sticky steering is used to describe the poor return of the steering wheel to center after a turn or the steering correction is completed. Ride Height Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 7468 Front Ride Height Measurement Rear Ride Height Measurement Shimmy Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel resulting from large, side-to-side (lateral) tire/wheel movements. Shimmy is usually experienced near 64 km/h (40 mph), and can begin or be amplified when the tire contacts pot holes or irregularities in the road surface. Toe Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 7469 Positive Toe (Toe In) Positive Toe (Toe In) Negative Toe (Toe Out) Negative Toe (Toe Out) The vehicle toe setting: ^ affects tire wear and directional stability. ^ must be checked after adding aftermarket equipment, such as a snowplow or body. Wander Wander is the tendency of the vehicle to require frequent, random left and right steering wheel corrections to maintain a straight path down a level road. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment Alignment: Service and Repair Camber and Caster Adjustment 1. Remove the nuts and alignment plates. 2. Install the cams and the nuts. 3. Note: A pry bar can be used between the front suspension arm bushing joint and the frame pocket to aid in moving the farm. To increase the LF caster and camber, use the following steps. 1 To increase caster, move the front of the front suspension arm bushing joint outboard and move the rear of the front suspension arm bushing joint inboard. 2 To increase camber, move the front suspension arm bushing joint outboard equally. 4. To decrease the LF caster and camber, use the following steps. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 7472 1 To decrease caster, move the front of the front suspension arm bushing joint inboard and move the rear of the front suspension arm bushing joint outboard. 2 To decrease camber, move the front suspension arm bushing joint inboard equally. 5. Tighten the nuts. 6. Note: A pry bar can be used between the front suspension arm bushing joint and the frame pocket to aid in moving the arm. To increase RF caster and camber, use the following steps. 1 To increase caster, move the front of the front suspension arm bushing joint outboard and move the rear of the front suspension arm bushing joint inboard. 2 To increase camber, move the front suspension arm bushing joint outboard equally. 7. To decrease the RF caster and camber, use the following steps. 1 To decrease caster, move the front of the front suspension arm bushing joint inboard and move the rear of the front suspension arm bushing joint outboard. 2 To decrease camber, move the front suspension arm bushing joint inboard equally. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 7473 8. Increase the caster split. 1 Loosen the nuts. 2 Adjust the caster set bolts forward. 9. Decrease the caster split. 1 Loosen the nuts. 2 Adjust the caster set bolts rearward. 10. Tighten the nuts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 7474 Alignment: Service and Repair Ride Height Ride Height - Front Suspension 1. Drive the vehicle onto a drive-on lift. 2. Jounce the vehicle's front and rear suspension to normalize the vehicle static ride height. 3. Measure the distance between the center line of the front suspension lower arm bushing bolt and the lift. Record the measurement. 4. Measure the distance between the front wheel spindle (lowest point) and the lift. Record the measurement. 5. Determine ride height. ^ Subtract measurement 1 from measurement 2. This is the ride height. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 7475 6. Note: The torsion bar adjusting bolt is coated with adhesive that wears; off after disassembly. If the torsion bar system is ever disassembled or the torsion bar adjusting bolt is ever removed, use a new torsion bar adjusting bolt when re-assembling. Adjust the torsion bars (height) as necessary by tightening or loosening the torsion bar adjusting bolt. ^ Tighten the torsion bar adjusting bolt to increase the torque or raise the height. ^ Loosen the torsion bar adjusting bolt to decrease the torque or lower the height. Ride Height - Vehicle Dynamic Suspension Special Service Tool(s) 1. Connect scan tool to the Data Link Connector (DLC). 2. Select the RIDE CONTROL OUTPUT screen and turn on the following solenoids to vent the entire system of air and to lower the vehicle to its lowest attainable height: ^ REAR FILL (rear fill solenoid). ^ GATE VALVE (gate solenoid). ^ VENT (vent solenoid). 3. Close all doors including the liftgate and liftgate window. 4. Reopen any door (to ensure that the height will not change until the internal electronic calibration is complete). 5. Park the vehicle on a flat surface. 6. From the function menu, quickly select RIDE HEIGHT CALIBRATION. 7. Note the warning on the scan tool screen and follow the directions. 8. Lower the vehicle and clear all stored Diagnostic Trouble Codes (DTCs). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 7476 Alignment: Service and Repair Toe Adjustment 1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering wheel in the "straight forward" position by attaching a rigid link from the steering wheel to the brake pedal. 3. Check the toe settings; follow the manufacturer's instructions. 4. Note: Do not allow the steering gear bellows to twist when the front wheel spindle tie-rod (3280) is rotated. Remove the clamps. 5. Loosen the nuts. ^ Clean and lubricate the nut(s) and front wheel spindle tie-rod threads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 7477 6. Rotate the front wheel spindle tie-rods. 7. Tighten the nuts. 8. Install the clamps. 9. Recheck the toe settings; follow the manufacturer's instructions. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 7483 Compressor/Pump Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications Suspension Control Module: Specifications Air Suspension Control Module Mounting Screws 18 - 27 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 7487 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 7488 Suspension Control Module: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 7489 Suspension Control Module: Service and Repair Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Note: Ride heights must be reset for the air suspension module whenever the air suspension module is replaced. Disconnect the battery negative ground cable. 2. Remove the center instrument panel finish panel. 1 Remove the center instrument panel finish panel screws. 2 Disconnect the electrical connectors and remove the center panel finish panel. 3. Remove the air suspension control module. 1 Remove the air suspension control module screws. 2 Slide the air suspension control module down and out of the support bracket. 4. Disconnect the air suspension control module electrical connectors and remove the air suspension control module. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 7490 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Note: When installing a new air suspension control module, ride height adjustment must be performed. Ride Height Adjustments To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Page 7497 Ride Height Sensor: Service and Repair Removal WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing of an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Remove the spare tire 3. Disconnect the height sensor electrical connector and remove the electrical connector harness from the frame and apron to separate the push-in fasteners 4. Release the upper and lower spring clip and pull the sensor from the ball studs. Installation 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Service and Repair Suspension Mode Switch: Service and Repair Removal 1. Remove the jack storage access cover. 2. Remove the retaining screw and air suspension switch bracket. 3. Remove the air suspension switch. 1 Disconnect the electrical connector. 2 Press the retaining clips and remove the air suspension switch from the bracket. Installation 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair Special Tool(s) Special Service Tool(s) Removal 1. Remove the brake disc and hub. 2. Remove the front brake anti-lock sensor. 1 Remove the anti-lock sensor electrical wire from the clamp, 2 Remove the bolt and position the sensor aside. 3. Remove the tie rod end castellated nut. 1 Remove the cotter pin. 2 Remove the castellated nut. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 7505 4. Use the Pitman Arm Puller to separate the tie rod end from the front wheel spindle. 5. Use a suitable jack stand to support the front suspension lower arm. 6. CAUTION: To avoid possible damage to the front wheel spindle, secure the spindle to keep it from tilting before removing the pinch bolt and nut. Remove the pinch bolt and nut from the front wheel spindle. 7. Remove the lower ball joint castellated nut. 1 Remove the lower ball joint cotter pin. 2 Remove the lower ball joint castellated nut. 8. Use the Pitman Arm Puller to remove the front wheel spindle. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 7506 1. Note: Install the cotter pin into the lower ball joint from outboard to inboard with the fingers bent together at a right angle. Failure to do so will cause damage to the wheel and tire assembly. Install the lower ball joint castellated nut. 1 Position the front wheel spindle to the lower ball joint. 2 Install the lower ball joint castellated nut. 3 Install a new cotter pin. 2. Install the pinch bolt and nut. 1 Position the front wheel spindle. 2 Install the pinch bolt and nut. 3. Remove the jack from under the front suspension lower arm. 4. CAUTION: Install the cotter pin into the lower ball joint from outboard to inboard with the fingers bent together at a right angle. Failure to do so will cause damage to the wheel and tire assembly. Connect the tie rod end to the front wheel spindle. 1 Position the tie rod end. 2 Install the tie rod end castellated nut. 3 Install a new cotter pin. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 7507 5. Install the front brake anti-lock sensor and position the anti-lock sensor electrical wire in the clamp. 6. Install the brake disc and hub. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair Special Tools Special Service Tool(s) CAUTION: If the air is not purged from the power steering system correctly, premature power steering pump failure could result. The condition can occur on pre-delivery vehicles with evidence of aerated fluid or on vehicles that have had steering component repairs. 1. Note: A whine heard from the power steering pump may be caused by air in the system. The power steering purge procedure must be performed prior to any component repair for which power steering noise complaints arc accompanied by evidence of aerated fluid. Remove the reservoir cap. Check the fluid. ^ Use Motorcraft MERCON Multipurpose ATF XT-2-QDX or MERCON equivalent. 2. Tightly insert the stopper of the vacuum pump into the reservoir. 3. Start the vehicle. 4. Apply maximum vacuum and maintain it for a minimum of three minutes with the engine speed set at idle. 5. Release the vacuum and remove the vacuum pump. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 7512 6. CAUTION: Do not overfill the power steeling pump reservoir. Fill the reservoir. ^ Use Motorcraft MERCON Multipurpose ATF XT-2-QDX or MERCON equivalent. 7. Reinstall the vacuum pump. Apply and maintain maximum vacuum. 8. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump could occur. Cycle the steering wheel fully to the left and right every 30 seconds for approximately five minutes. 9. Stop the engine, release the vacuum, and remove the vacuum pump. 10. Install the reservoir cap. 11. Check fir fluid leaks at all of the connections. If the power steering fluid shows signs of air, repeat this procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Mercon V(R) Fluid Usage TSB 07-1-7 01/22/07 MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER STEERING SYSTEMS FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort 2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53 Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007 Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series 2000-2007 F-650, F-750 2006-2007 Low Cab Forward LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar 2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002 Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid for power steering systems originally requiring MERCON(R). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 7517 ACTION Beginning immediately all power steering 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 Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. CAUTION APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 7518 Power Steering Fluid: Specifications / / Power Steering Fluid Type MERCON(R) ATF Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Specifications Power Steering Fluid Cooler: Specifications Fluid Cooler Nuts 59 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Specifications > Page 7522 Power Steering Fluid Cooler: Service and Repair Removal 1. Disconnect the power steering return line hose at the power steering fluid cooler. ^ Allow the system to drain. 2. Remove the power steering fluid cooler to crossmember nuts. 3. Disconnect the power steering return hose. Remove the power steering fluid cooler. Installation 1. Follow the removal procedure in reverse order. 2. Fill, and leak check the system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Pressure Hose to Power Steering Pump 48 ft.lb Power Steering Pump Bolts 18 ft.lb Steering Gear Pressure Fittings 22 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications > Page 7526 Power Steering Line/Hose: Service and Repair Special Tools Special Service Tool(s) Removal 1. Refer to the Description and Operation for the hose routing and retention points. Installation 1. When connecting a fitting with a seal ring, a new seal ring must be installed. ^ The special tool is used to install the return line connector seal and the pressure line connector seal. 2. Fill and leak check the system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications Power Steering Pump: Mechanical Specifications Pump Pulley Bolts 18 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 7531 Power Steering Pump: Pressure, Vacuum and Temperature Specifications Flow Rate 2.1 - 2.5 gal/min Flow Rate @ 74 - 80 degrees C (165 - 175 degrees F) and Engine Speed Set at 1500 RPM Maximum Pressure 150 psi Maximum Pressure @ 74 - 80 deg C (165 - 175 deg F) and Engine Speed Set at 1500 RPM Minimum Flow Rate 0.95 gal/min Minimum Flow Rate @ 74 - 80 deg C (165 - 175 deg F), Power Steering Analyzer Set at 5,102 kPa (750 psi) and Engine Speed Set at Idle Relief Pressure 1300 - 1480 psi Flow Rate 2.2 - 2.6 gal/min Flow Rate @ 74 - 80 degrees C (165 - 175 degrees F) and Engine Speed Set at 1500 RPM Maximum Pressure 150 psi Maximum Pressure @ 74 - 80 deg C (165 - 175 deg F) and Engine Speed Set at 1500 RPM Minimum Flow Rate 1.15 gal/min Minimum Flow Rate @ 74 - 80 deg C (165 - 175 deg F), Power Steering Analyzer Set at 5,102 kPa (750 psi) and Engine Speed Set at Idle Relief Pressure 1300 - 1480 psi Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 7532 Power Steering Pump Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Power Steering Pump: Service and Repair Power Steering Pump Special Tools Special Service Tool(s) Removal 1. Remove the engine cooling fan. 2. Loosen the power steering pump pulley bolts. 3. Remove the drive belt. 4. Remove the power steering pump pulley. 1 Remove the bolts. 2 Remove the power steering pump pulley. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7535 5. Disconnect the power steering return line hose at the power steering fluid reservoir. ^ Allow the system to drain. 6. Disconnect the power steering pressure hose from the power steering pump. 7. Disconnect the power steering fluid reservoir outlet hose from the power steering pump. 1 Compress and move the power steering fluid reservoir outlet hose clamp. 2 Disconnect the power steering fluid reservoir outlet hose from the power steering pump. 8. Remove the power steering pump. 1 Remove the bolts. 2 Remove the power steering pump. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7536 1. Install the power steering pump. 1 Position the power steering pump. 2 Install the bolts. 2. Connect the power steering fluid reservoir outlet hose to the power steering pump. 1 Connect the power steering fluid reservoir outlet hose to the power steering pump. 2 Compress and move the power steering fluid reservoir outlet hose clamp into place. 3. Using the special tool, install a new seal on the power steering pressure hose. 4. Connect the power steering pressure hose to the power steering pump. 5. Connect the power steering return line hose to the power steering fluid reservoir. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7537 6. Install the power steering pump pulley. 1 Position the power steering pump pulley. 2 Install the bolts. 7. Install the drive belt. 8. Tighten the power steering pump pulley bolts. 9. Install the engine cooling fan. 10. Fill, and leak check the system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7538 Power Steering Pump: Service and Repair Power Steering Pump Pulley Removal 1. Remove the engine cooling fan. 2. Loosen the power steering pump pulley bolts. 3. Remove the drive belt. 4. Remove the power steering pump pulley. 1 Remove the bolts. 2 Remove the power steering pump pulley. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING:To reduce the risk of personal injury, do not use any memory saver devices. NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram See: Restraint Systems/Air Bag Systems. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7544 7. Remove the two steering wheel back cover plugs. 8. Remove the two driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. 10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical connector at the clockspring. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7545 11. Open the glove compartment door to access the passenger air bag module mounting screws. 12. Remove the two screws. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove box opening, push out on the passenger air bag module and separate it from the instrument panel. 14. Disconnect the electrical connector and remove the passenger air bag module. 15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the passenger air bag module electrical connector. Vehicles equipped with seat side air bags Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7546 16. Disconnect the passenger seat side air bag module electrical connector located under the passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector located under the driver seat. 19. Connect the restraint system diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical connector. All vehicles 20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground cable. Reactivation Procedure All vehicles 1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles equipped with seat side air bags 3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side air bag module electrical connector located under the driver seat. 4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint system diagnostic tool from the body harness side of the passenger seat side air bag module electrical connector located under the passenger seat. 6. Connect the passenger seat side air bag module electrical connector All vehicles 7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air bag module electrical connector. 8. Install the passenger air bag module. 9. Connect the passenger air bag module electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7547 10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical connector at the clockspring. 11. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag module to the steering wheel. 12. Install the two driver air bag module retaining bolts. 13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON. 15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 17. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7548 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle battery connected? Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7549 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Prove out the system means to turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Service and Repair Key Reminder Switch: Service and Repair For further information regarding the service of this component and the system that it is part of, please refer to Instrument Panel, Gauges and Warning indicators; Service and Repair; Warning Devices. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Ignition Switch Lock Cylinder Steering Column Lock: Service and Repair Ignition Switch Lock Cylinder Functional Lock Cylinder Removal 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. 2. Prove out the air bag system. Non-Functional Lock Cylinder Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Ignition Switch Lock Cylinder > Page 7557 WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. 4. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Ignition Switch Lock Cylinder > Page 7558 5. Remove the bearing retainer. 6. Remove the bearing and the gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. Installation WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Ignition Switch Lock Cylinder > Page 7559 1. Note: Use a new ignition switch lock cylinder. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. 2. Prove out the air bag system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Ignition Switch Lock Cylinder > Page 7560 Steering Column Lock: Service and Repair Key Release Button Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, remove the tilt wheel handle and shank. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Ignition Switch Lock Cylinder > Page 7561 2 Remove the upper and lower steering column shrouds. 5. Remove the key release lever. 1 Remove the key release lever bolt. 2 Remove the release lever handle and the spring. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications Steering Gear: Specifications Type Rack and Pinion Steering Gear Turns (Stop to Stop) 3.2/4.0 To Crossmember Stud Bolts and Nuts 111 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7565 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7566 Steering Gear: Testing and Inspection 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. Rotate the steering wheel to the RH stop, then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. 4. Turn the steering wheel another 90° Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50 200 Hz) shudder is present, this is a normal steering system condition. 7. If a loud grunt is heard, or a strong shudder is felt, fill and purge the power steering system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7567 Steering Gear: Service and Repair Removal 1. Place front wheels in the straight ahead position. Do not lock the steering column. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle. 3. Remove the front wheel and tire assemblies. 4. Remove the radiator air deflector. 1 Remove the bolts. 2 Remove the radiator air deflector. 5. Loosen the LH tie-rod end jam nut. 6. Disconnect the tie-rod ends. 1 Remove and discard the cotter pins. 2 Remove the castellated nuts. 3 Disconnect the tie-rod ends from the steering knuckles. a Do not damage the tie-rod end boots. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7568 7. Remove the LH tie-rod end. ^ Count and record the number of turns required to remove the tie-rod end. 8. Remove the front stabilizer bar. ^ Mark the driver side end of the stabilizer bar for correct installation. 9. Remove the power steering cooler to crossmember nuts. 10. Remove the power steering fluid cooler. 1 Separate the power steering fluid return hose from the power steering fluid cooler. ^ Allow the system to drain. 2 Disconnect the power steering return line hose. 3 Remove the power steering fluid cooler. 11. Disconnect the lines at the gear. 1 Disconnect the power steering pressure hose. 2 Disconnect the power steering return hose. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7569 12. Plug ends of fluid lines and ports in steering gear to prevent damage and entry of dirt. 13. Rotate the steering column shaft to access the intermediate shaft pinch bolt. Remove the pinch bolt. 14. Lower the vehicle. 15. Turn the steering wheel back to the straight ahead position. Turn the ignition key to the locked position. 16. Raise the vehicle. 17. CAUTION: Do not rotate the steering wheel when the lower steering column shaft is disconnected or damage to the air bag sliding contact will result. Disconnect the intermediate shaft from the steering gear input shaft. 18. CAUTION: Hold the tops of the steering gear to crossmember stud bolts to avoid damaging the steering gear fluid transfer tubes. Remove the nuts. 19. Remove the stud bolts and washers. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7570 20. Remove the steering gear to crossmember insulator bushings. 21. Rotate the steering gear control valve housing toward the front of the vehicle. 22. Turn the steering gear input shaft to the right until the stop is reached. 23. Move the steering gear as far to the RH side of the vehicle as possible. 24. Move the LH front wheel spindle tie-rod forward to clear the frame crossmember. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7571 25. Remove the steering gear from the vehicle. Installation 1. Using the special tool, install new seals on the power steering return hose and power steering pressure hose. 2. Note: Make sure the steering gear input shaft is turned to the left until the stop is reached. Note: Handle the steering gear with caution to avoid damage to the fluid transfer tubes and to avoid dimples in the tie-rod boots. Turn the steering gear input shaft to the right until the stop is reached. Note the number of turns. 3. Note: Make sure the steering gear control valve housing is turned toward the front of the vehicle. Install the steering gear into the RH opening of the crossmember. 4. Move the steering gear as far to the RH side of the vehicle as possible. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7572 5. Move the LH front wheel spindle tie-rod into the opening in the crossmember and move the steering gear into position. 6. To place the steering gear in the straight ahead position, turn the steering gear input shaft to the left by half the number of turns recorded previously. 7. Rotate the steering gear control valve housing toward the rear of the vehicle. 8. Install the steering gear to crossmember insulator bushings as shown. ^ The large end of the metal sleeve must be positioned downward. ^ Check that the mounting surfaces on the crossmember are clean and free of debris. 9. Install the steering gear to crossmember washers and stud bolts. ^ The dished side of the washers face down. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7573 10. CAUTION: Hold the tops of the steering gear to crossmember stud bolts to avoid damaging the steering gear fluid transfer tubes. Install the nuts. 11. CAUTION: Do not rotate the steering wheel when the lower steering column shaft is disconnected or damage to the air bag sliding contact will result. Connect the intermediate shaft to the steering gear input shaft. Install the pinch bolt. 12. Install the steering gear fluid lines. 1 Install the power steering return hose and then tighten tube nut. 2 Install the power steering pressure hose and tighten the tube nut. 13. Install the power steering fluid cooler. 1 Connect the power steering return line hose. 2 Connect the power steering return hose. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7574 3 Position the power steering fluid cooler and install the nuts. 14. Install the front stabilizer bar. ^ Orientate the front stabilizer bar as noted during removal. 15. Install the LH tie-rod end on the front wheel spindle tie-rod. ^ Rotate the tie-rod end the number of turns recorded during removal. 16. Connect the tie-rod ends to the steering knuckles. 1 Position the tie-rod ends on the steering knuckles. 2 Install the castellated nuts. 3 Install the new cotter pins. ^ Check that the brake dust shields are not bent and are not in contact with the outer tie-rod boot seals. 17. Tighten the tie-rod jam nuts. 18. Install the radiator air deflector. 1 Position the radiator air deflector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7575 2 Install the bolts. 19. Install the front wheel and tire assemblies. 20. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. 21. Fill and leak check the power steering system. 22. Check the wheel alignment. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications Steering Shaft: Specifications Lower Intermediate Shaft Pinch Bolt 36 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose Steering Wheel: Customer Interest Interior - Leather Wrapping On Steering Wheel Is Loose TSB 07-4-3 03/05/07 LEATHER - WRAPPED STEERING WHEEL - LEATHER COMING LOOSE FORD: 2000-2005 Thunderbird 2000-2007 Crown Victoria, Focus, Mustang, Taurus 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1999-2003 Windstar 1999-2008 F-Super Duty 2000-2005 Excursion 2000-2007 E-Series, Expedition, Explorer, Ranger 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2001-2008 Escape 2004-2007 F-150, Freestar 2005-2008 Escape Hybrid 2007 Edge 2004-2007 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 Lincoln LS 2000-2007 Town Car 2006 Zephyr 2007 MKZ 2000-2007 Navigator 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 2000-2005 Sable 2000-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 2000-2007 Mountaineer 2004-2007 Monterey 2005-2008 Mariner 2006-2008 Mariner Hybrid This article supersedes TSB 04-24-3 to update the vehicle model years. ISSUE Some vehicles equipped with leather-wrapped steering wheels may exhibit the leather coming loose from the spoke area. ACTION Apply Motorcraft Instant Gel Adhesive to re-adhere the loose leather to the wheel spoke. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF RE-ADHERING LEATHER TO THE FRONT SIDE OF THE STEERING WHEEL ONLY, OMIT STEPS 1 AND 6. STEERING WHEEL/AIR BAG ASSEMBLY REMOVAL IS NECESSARY ONLY WHEN REPAIRING LOOSE LEATHER ON THE BACKSIDE OF THE STEERING WHEEL. CAUTION AVOID SKIN CONTACT WITH MOTORCRAFT INSTANT GEL ADHESIVE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose > Page 7587 1. Remove the steering wheel (ONLY NECESSARY TO REPAIR BACKSIDE OF STEERING WHEEL). Refer to Workshop Manual Sections 211-04 and 501-20B. 2. Fold loose leather out of the way. 3. Apply Motorcraft Instant Gel Adhesive evenly over the wheel spoke. 4. Fold the leather back into its original position. 5. Smooth the leather tuck in for neat appearance, and apply pressure until the leather is bonded to the wheel spoke (apply pressure for at least 30 seconds). NOTE THE ADHESIVE SHOULD BE COMPLETELY SET AFTER 5 MINUTES. DO NOT PULL ON THE REPAIR AREA. 6. Reinstall steering wheel. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT070403 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 3600 33 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose Steering Wheel: All Technical Service Bulletins Interior - Leather Wrapping On Steering Wheel Is Loose TSB 07-4-3 03/05/07 LEATHER - WRAPPED STEERING WHEEL - LEATHER COMING LOOSE FORD: 2000-2005 Thunderbird 2000-2007 Crown Victoria, Focus, Mustang, Taurus 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1999-2003 Windstar 1999-2008 F-Super Duty 2000-2005 Excursion 2000-2007 E-Series, Expedition, Explorer, Ranger 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2001-2008 Escape 2004-2007 F-150, Freestar 2005-2008 Escape Hybrid 2007 Edge 2004-2007 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 Lincoln LS 2000-2007 Town Car 2006 Zephyr 2007 MKZ 2000-2007 Navigator 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 2000-2005 Sable 2000-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 2000-2007 Mountaineer 2004-2007 Monterey 2005-2008 Mariner 2006-2008 Mariner Hybrid This article supersedes TSB 04-24-3 to update the vehicle model years. ISSUE Some vehicles equipped with leather-wrapped steering wheels may exhibit the leather coming loose from the spoke area. ACTION Apply Motorcraft Instant Gel Adhesive to re-adhere the loose leather to the wheel spoke. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF RE-ADHERING LEATHER TO THE FRONT SIDE OF THE STEERING WHEEL ONLY, OMIT STEPS 1 AND 6. STEERING WHEEL/AIR BAG ASSEMBLY REMOVAL IS NECESSARY ONLY WHEN REPAIRING LOOSE LEATHER ON THE BACKSIDE OF THE STEERING WHEEL. CAUTION AVOID SKIN CONTACT WITH MOTORCRAFT INSTANT GEL ADHESIVE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose > Page 7593 1. Remove the steering wheel (ONLY NECESSARY TO REPAIR BACKSIDE OF STEERING WHEEL). Refer to Workshop Manual Sections 211-04 and 501-20B. 2. Fold loose leather out of the way. 3. Apply Motorcraft Instant Gel Adhesive evenly over the wheel spoke. 4. Fold the leather back into its original position. 5. Smooth the leather tuck in for neat appearance, and apply pressure until the leather is bonded to the wheel spoke (apply pressure for at least 30 seconds). NOTE THE ADHESIVE SHOULD BE COMPLETELY SET AFTER 5 MINUTES. DO NOT PULL ON THE REPAIR AREA. 6. Reinstall steering wheel. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT070403 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 3600 33 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 7594 Steering Wheel: Specifications Steering Wheel Bolt 25 - 34 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 7595 Steering Wheel: Service and Repair Special Tool(s) Special Service Tool(s) Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Note: Make sure the wheels are in the straight-ahead position. 1. Disconnect the battery cable and wait at least one minute. ^ Disconnect the battery ground cable. ^ Disconnect the battery to starter relay cable. 2. Remove the driver air bag module. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 7596 3. Remove the steering wheel bolt. 4. CAUTION: Removing the steering wheel without using a puller can damage the column bearings. Use the 2-Jaw Puller to remove the steering wheel. 5. Remove and discard the original steering wheel bolt. 6. Remove the steering wheel while routing the wires from the air bag sliding contact through the steering wheel. Installation WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 7597 WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Follow the removal procedure in reverse order. 2. Connect the battery cables. 3. Prove out the air bag system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications Tie Rod End: Specifications Tie Rod End Nut 44 - 59 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid Ball Joint: Specifications Front Suspension Balljoint Inspection Job Aid Front Lower Ball Joint Measurement .................................................................................................................................................. Between lower control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.032 in (0-0.8mm) Reference Diagram ............................................................................................................................. ............................................................................. A Front Upper Ball Joint Measurement .................................................................................................................................................. Between upper control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.008 in (0-0.2mm) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 7607 Reference Diagram ............................................................................................................................. ............................................................................. C Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 7608 Ball Joint: Specifications Ball Joint Radial Play Lower Ball Joint Maximum 1/32 in Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 7609 Ball Joint: Specifications Ball Joint Radial Play Upper Ball Joint Maximum 1/32 in Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Front Suspension Balljoint Inspection Job Aid Ball Joint: Testing and Inspection Front Suspension Balljoint Inspection Job Aid Front Lower Ball Joint Measurement .................................................................................................................................................. Between lower control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.032 in (0-0.8mm) Reference Diagram ............................................................................................................................. ............................................................................. A Front Upper Ball Joint Measurement .................................................................................................................................................. Between upper control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.008 in (0-0.2mm) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Front Suspension Balljoint Inspection Job Aid > Page 7612 Reference Diagram ............................................................................................................................. ............................................................................. C Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Front Suspension Balljoint Inspection Job Aid > Page 7613 Ball Joint: Testing and Inspection Ball Joint, Lower 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Prior to performing any inspection of the ball joints, inspect the front wheel bearings. 3. Position a safety stand beneath the front suspension lower arm to be tested. 4. While an assistant pulls and pushes the bottom of the tire, observe the relative movement between the lower spindle arm and the front suspension lower arm ball joint. Any movement at or exceeding the specification indicates a worn or damaged lower ball joint. Install a new ball joint as necessary. 5. While an assistant pulls and pushes the top of the tire, observe the relative movement between the upper spindle arm and the front suspension upper ball joint. Movement at or exceeding the specification indicates a worn or damaged upper ball joint or loose pinch bolt joint. Tighten pinch bolt and nut as necessary. Install a new upper ball joint as necessary. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Front Suspension Balljoint Inspection Job Aid > Page 7614 Ball Joint: Testing and Inspection Ball Joint, Upper 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Prior to performing any inspection of the ball joints, inspect the front wheel bearings. 3. Position a safety stand beneath the front suspension lower arm to be tested. 4. While an assistant pulls and pushes the bottom of the tire, observe the relative movement between the lower spindle arm and the front suspension lower arm ball joint. Any movement at or exceeding the specification indicates a worn or damaged lower ball joint. Install a new ball joint as necessary. 5. While an assistant pulls and pushes the top of the tire, observe the relative movement between the upper spindle arm and the front suspension upper ball joint. Movement at or exceeding the specification indicates a worn or damaged upper ball joint or loose pinch bolt joint. Tighten pinch bolt and nut as necessary. Install a new upper ball joint as necessary. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 7615 Ball Joint: Service and Repair Ball Joint-Lower Special Tool(s) Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the wheel and tire assembly. 3. CAUTION: Do not allow the disc brake caliper to hang suspended from the brake hose. Provide a suitable support. Remove the caliper support bracket bolts, then position the caliper and support bracket aside. 4. Disconnect the front anti-lock brake sensor (ABS) wire from the vehicle frame. 1. Disconnect the ABS electrical connector. 2. Unclip the front ABS wire from the vehicle frame. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 7616 5. Using a suitable jack, support the front suspension lower arm. 6. Remove the tie-rod end castellated nut. ^ Remove and discard the cotter pin and the castellated nut. 7. CAUTION: Do not use a hammer to separate the tie-rod from the wheel knuckle or damage to the wheel knuckle will result. CAUTION: Do not damage the tie-rod boot when installing the special tool. Using the special tool, separate the tie-rod end from the front wheel knuckle. 8. Remove the lower ball joint castellated nut. 1. Remove and discard the cotter pin. 2. Remove and discard the castellated nut. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 7617 9. Using the special tool, separate the front wheel knuckle from the front suspension lower arm. Then, loosely install the lower ball joint castellated nut. 10. Remove the pinch bolt and nut. 11. Remove the hand-tightened lower ball joint castellated nut, then remove the front wheel knuckle. 12. Remove the snap ring from the ball joint. Discard the snap ring. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 7618 13. Using a suitable ball joint remover tool, remove the ball joint. 14. CAUTION: Do not damage the ball joint boot when installing the special tool. NOTE: Clean and inspect the control arm ball joint bore for damage before installing a new ball joint. NOTE: Make sure the new ball joint snap ring is fully seated. To install, reverse the removal procedure. ^ Always install new castellated nuts and cotter pins. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Solid Rear Axle Control Arm Bushing: Service and Repair Solid Rear Axle Removal and Installation NOTE: The control arm bushings are not serviced separately. If the bushings require service, the front suspension lower arm or the front suspension upper arm will have to be installed new. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Solid Rear Axle > Page 7624 Control Arm Bushing: Service and Repair Independent Rear Suspension Lower Arm-Bushing Lower Arm-Bushing Removal and Installation NOTE: The lower arm bushings are not serviced separately. If the bushings require service, a new lower arm must be installed. Upper Arm Bushing Upper Arm Bushing Removal and Installation 1. Raise and support the vehicle. 2. Remove and discard the nut. 3. Remove the bolts and the flag nuts. ^ Discard the flag nuts. 4. Rotate the bushing upwards and remove the bushing. 5. CAUTION: Make sure the upper arm-to-frame mounting bolts are routed through the frame and the arm before tightening. NOTE: Do not tighten the bushing-to-arm nut until the vehicle is at curb ride height. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Solid Rear Axle > Page 7625 To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System Information > Service and Repair Rear Cross-Member: Service and Repair CROSSMEMBER - TRANSMISSION SUPPORT Materials Materials Removal and Installation 1. Raise and support the vehicle. 2. Loosen, but do not remove, the nuts retaining the transmission insulator to the crossmember. 3. Support the transmission. 4. Remove the six bolts retaining the crossmember to the frame. 5. Remove the nuts and the crossmember. 6. NOTE: Apply Threadlock 262 E2FZ-19554-B meeting Ford specification WSK-M2G351-A6 or equivalent to the transmission crossmember mounting bolts. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair Special Tool(s) Special Service Tool(s) Removal 1. Remove the brake disc and hub. 2. Remove the front brake anti-lock sensor. 1 Remove the anti-lock sensor electrical wire from the clamp, 2 Remove the bolt and position the sensor aside. 3. Remove the tie rod end castellated nut. 1 Remove the cotter pin. 2 Remove the castellated nut. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 7633 4. Use the Pitman Arm Puller to separate the tie rod end from the front wheel spindle. 5. Use a suitable jack stand to support the front suspension lower arm. 6. CAUTION: To avoid possible damage to the front wheel spindle, secure the spindle to keep it from tilting before removing the pinch bolt and nut. Remove the pinch bolt and nut from the front wheel spindle. 7. Remove the lower ball joint castellated nut. 1 Remove the lower ball joint cotter pin. 2 Remove the lower ball joint castellated nut. 8. Use the Pitman Arm Puller to remove the front wheel spindle. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 7634 1. Note: Install the cotter pin into the lower ball joint from outboard to inboard with the fingers bent together at a right angle. Failure to do so will cause damage to the wheel and tire assembly. Install the lower ball joint castellated nut. 1 Position the front wheel spindle to the lower ball joint. 2 Install the lower ball joint castellated nut. 3 Install a new cotter pin. 2. Install the pinch bolt and nut. 1 Position the front wheel spindle. 2 Install the pinch bolt and nut. 3. Remove the jack from under the front suspension lower arm. 4. CAUTION: Install the cotter pin into the lower ball joint from outboard to inboard with the fingers bent together at a right angle. Failure to do so will cause damage to the wheel and tire assembly. Connect the tie rod end to the front wheel spindle. 1 Position the tie rod end. 2 Install the tie rod end castellated nut. 3 Install a new cotter pin. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 7635 5. Install the front brake anti-lock sensor and position the anti-lock sensor electrical wire in the clamp. 6. Install the brake disc and hub. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair Rear Knuckle: Service and Repair Wheel Knuckle, Independent Rear Suspension Special Tool(s) 1. CAUTION: Do not loosen the axle wheel hub retainer until the wheel and tire are removed from the vehicle. Wheel bearing damage will occur if the wheel bearing is unloaded with the weight of the vehicle applied. Remove the wheel and tire assembly. 2. NOTE: Have an assistant press the brake pedal to keep the axle from turning. Remove the nut and washer. ^ Discard the nut. 3. Remove the brake shield. 4. CAUTION: Do not damage the boot while separating the toe link from the knuckle. Remove the nut and bolt and separate the toe link from the wheel knuckle. ^ Discard the nut. 5. CAUTION: Do not damage the boot while separating the ball joint from the knuckle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 7639 Remove the nut and bolt and separate the upper ball joint from the wheel knuckle. ^ Discard the nut. 6. CAUTION: Do not use a hammer to separate the outboard CV joint from the hub. Damage to the threads and internal CV joint components may result. Using the special tool, press the outboard CV joint until it is loose from the hub. 7. Remove the nut and bolt and the wheel knuckle, hub and bearing as an assembly. ^ Discard the nut. 8. If necessary, remove the hub and bearing. 9. To install. reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle Alignment Link > Component Information > Service and Repair Rear Knuckle Alignment Link: Service and Repair Toe Link, Independent Rear Suspension 1. Remove the wheel and tire assembly. 2. Remove the nut and bolt and separate the toe link from the wheel knuckle. 3. Remove the nut and the toe link. 4. To install, reverse the removal procedure. 5. Check and, if necessary, adjust the rear toe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 7647 Compressor/Pump Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications Suspension Control Module: Specifications Air Suspension Control Module Mounting Screws 18 - 27 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 7651 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 7652 Suspension Control Module: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 7653 Suspension Control Module: Service and Repair Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Note: Ride heights must be reset for the air suspension module whenever the air suspension module is replaced. Disconnect the battery negative ground cable. 2. Remove the center instrument panel finish panel. 1 Remove the center instrument panel finish panel screws. 2 Disconnect the electrical connectors and remove the center panel finish panel. 3. Remove the air suspension control module. 1 Remove the air suspension control module screws. 2 Slide the air suspension control module down and out of the support bracket. 4. Disconnect the air suspension control module electrical connectors and remove the air suspension control module. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 7654 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Note: When installing a new air suspension control module, ride height adjustment must be performed. Ride Height Adjustments To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Page 7660 Ride Height Sensor: Service and Repair Removal WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing of an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Remove the spare tire 3. Disconnect the height sensor electrical connector and remove the electrical connector harness from the frame and apron to separate the push-in fasteners 4. Release the upper and lower spring clip and pull the sensor from the ball studs. Installation 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Service and Repair Suspension Mode Switch: Service and Repair Removal 1. Remove the jack storage access cover. 2. Remove the retaining screw and air suspension switch bracket. 3. Remove the air suspension switch. 1 Disconnect the electrical connector. 2 Press the retaining clips and remove the air suspension switch from the bracket. Installation 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Specifications Spindle: Specifications To Lower Ball Joint Nut 83 - 113 ft.lb To Upper Ball Joint Nut 35 - 46 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications Stabilizer Link: Specifications Front Stabilizer Bar Link Nuts 15 - 21 ft.lb Rear Stabilizer Bar to Link Nut 50 - 68 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Service and Repair Air Dryer: Service and Repair Removal 1. Remove the air compressor. 2. Remove the air compressor drier. 1 Remove the screw. 2 Rotate 90° to unlock then remove the air compressor drier. Installation 1. Note: Inspect the O-ring for damage and replace as necessary. Lubricate the solenoid seal area with Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331A or equivalent meeting Ford specification ESE-M1C171-A. Note: When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. Note: Ride height adjustments must be performed after the air compressor/drier is installed. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Service and Repair > Air Line Fluid Purge Air Line: Service and Repair Air Line Fluid Purge Note: Perform this procedure if fluid (water or oil) is found in the rear air lines. Purge fluid from air lines and replace affected components. 1. Disconnect air line at compressor air drier that is connected to front fill solenoid inlet. 2. Disconnect air line at inlet of front fill solenoid. 3. Connect stop air line to disconnected air line and blow out any water 4. Reconnect air line. 5. Disconnect air line at compressor air drier that is connected to the rear fill solenoid inlet. 6. Disconnect air line at RR shock absorber. 7. Connect scan tool to Data Link Connector (DLC). 8. Using the RIDE CONTROL OUTPUT command, turn on the following actuators: ^ REAR_FIL (rear fill solenoid) ON. 9. Connect shop air line to disconnected air line and blow out any water. 10. Reconnect air line at RR shock absorber. 11. Disconnect air line at LR shock absorber. 12. Using the RIDE CONTROL OUTPUT command, turn on the following actuators: ^ REAR_FIL(rearfill solenoid) ON. ^ GATE VALVE (front and rear gate solenoids) ON. 13. Connect shop air line to disconnected air line and blow out any water. 14. If oil was present in air lines, replace BOTH LR and RR shock absorbers. (Do not replace s hock absorbers if only water is in the lines.) 15. Replace compressor air drier. 16. Reconnect air line. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Service and Repair > Air Line Fluid Purge > Page 7679 Air Line: Service and Repair Air Line Repair Note: A soapy water solution can be applied to the air lines to verify the location of air leaks. 1. If a leak is detected in an air line, it can be repaired by carefully making a good, clean, straight cut. Trim back the outer covering of the air line 16 - 20 mm (0.63 - 0.78 inch) to reveal the white inner line. Install a repair fitting and wrap securely with electrical tape. 2. If multiple leaks are detected, replace the entire air line. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Specifications Compressor/Pump: Specifications Air Compressor Assembly to Frame Mounting Bolts 13 - 17 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Specifications > Page 7683 Compressor/Pump: Service and Repair Removal WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing of an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Remove the spare tire. 3. Disconnect the air compressor electrical connector. 4. Disconnect the air line from the drier. 1 Compress the quick connect locking ring and pull out the air line. 2 Remove the air line from the drier. 5. Remove the air compressor assembly from the vehicle. 1 Remove the air compressor bolts. 2 Remove the air compressor assembly. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Specifications > Page 7684 1. Note: When installing the air lines make sure the white air line is fully inserted into the fitting for correct installation. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 7688 Compressor/Pump Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Solenoid Valve-Rear Fill Level Control Solenoid Valve: Service and Repair Solenoid Valve-Rear Fill Special Service Tool(s) Removal 1. Connect New Generation STAR (NGS) Tester to the Data Link Connector (DLC). 2. Select the RIDE CONTROL OUTPUT screen and turn on the following solenoids to vent the entire system of air and to lower the vehicle to its lowest attainable height: ^ REAR FILL (rear fill solenoid). ^ GATE VALVE (gate solenoid[s]). ^ VENT (vent solenoid). 3. Raise and support the vehicle. 4. Remove the spare tire. 5. Remove the solenoid valve from the frame. 6. Compress the quick connect locking ring and pull out the air line. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Solenoid Valve-Rear Fill > Page 7693 7. Disconnect the solenoid valve electrical connector. Installation 1. Note: When installing the air lines make sure the white air line is fully inserted into the fitting for correct installation. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Solenoid Valve-Rear Fill > Page 7694 Level Control Solenoid Valve: Service and Repair Solenoid Valve-Rear Gate Special Service Tool(s) Removal 1. Connect scan tool to the Data Link Connector (DLC). 2. Select the RIDE CONTROL OUTPUT screen and turn on the following solenoids to vent the entire system of air and to lower the vehicle to its lowest attainable height: ^ REAR FILL (rear fill solenoid). ^ GATE VALVE (gate solenoid[s]). ^ VENT (vent solenoid). 3. Raise and support the vehicle. 4. Remove the spare tire. 5. Remove the evaporative canister. 6. Remove the solenoid valve from the frame. 7. Compress the quick connect locking ring and pull out the air line. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Solenoid Valve-Rear Fill > Page 7695 8. Disconnect the solenoid valve electrical connector. Installation 1. Note: When installing the air lines make sure the white air line is fully inserted into the fitting for correct installation. To install, reverse the removal Procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Locations > Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Locations > Page 7700 Ride Height Sensor: Service and Repair Removal WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing of an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Remove the spare tire 3. Disconnect the height sensor electrical connector and remove the electrical connector harness from the frame and apron to separate the push-in fasteners 4. Release the upper and lower spring clip and pull the sensor from the ball studs. Installation 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Specifications Suspension Control Module: Specifications Air Suspension Control Module Mounting Screws 18 - 27 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Specifications > Page 7704 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Specifications > Page 7705 Suspension Control Module: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Specifications > Page 7706 Suspension Control Module: Service and Repair Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Note: Ride heights must be reset for the air suspension module whenever the air suspension module is replaced. Disconnect the battery negative ground cable. 2. Remove the center instrument panel finish panel. 1 Remove the center instrument panel finish panel screws. 2 Disconnect the electrical connectors and remove the center panel finish panel. 3. Remove the air suspension control module. 1 Remove the air suspension control module screws. 2 Slide the air suspension control module down and out of the support bracket. 4. Disconnect the air suspension control module electrical connectors and remove the air suspension control module. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Specifications > Page 7707 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Note: When installing a new air suspension control module, ride height adjustment must be performed. Ride Height Adjustments To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Service and Repair Suspension Mode Switch: Service and Repair Removal 1. Remove the jack storage access cover. 2. Remove the retaining screw and air suspension switch bracket. 3. Remove the air suspension switch. 1 Disconnect the electrical connector. 2 Press the retaining clips and remove the air suspension switch from the bracket. Installation 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications Suspension Spring ( Coil / Leaf ): Specifications Rear Spring Shackle Lower Bolt and Nut 85 ft.lb Rear Spring to Front Frame Bracket Bolt and Nut 66 ft.lb Rear Spring U-bolt Nut 76 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Shock Absorber and Spring Assembly Removal and Installation 1. Remove the wheel and tire assembly. 2. Remove and discard the nuts. 3. Remove the nut and the stabilizer bar link. ^ Discard the nut. 4. Remove the nut and the bolt. ^ Discard the nut. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Rear > Page 7716 5. Remove the bolt, flag nut and the shock absorber and spring as an assembly. ^ Discard the flag nut. 6. Using a suitable spring compressor, compress the spring until the tension is released from the shock absorber. 7. While holding the flats of the washer, remove the nut. ^ Remove the shock absorber. ^ Discard the nut. 8. Remove the washer, bushing and the upper mount. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Rear > Page 7717 9. Remove the insulator. 10. Remove the dust shield. 11. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Rear > Page 7718 Suspension Spring ( Coil / Leaf ): Service and Repair Leaf Spring Spring Tools Special Service Tool(s) Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air shocks, which can result in shifting of the vehicle during these operations. Turn the air suspension service switch off, if so equipped. 2. Raise the vehicle and install safety stands. 3. Remove the wheel and tire assembly. 4. Use the Hi-Lift Jack to support the rear axle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Rear > Page 7719 5. Separate the rear spring from the rear axle. 1 Remove the four nuts. 2 Remove the two U-bolts. 3 Position the rear spring plate aside. 6. Remove the rear spring. 1 Remove the bolt and nut. 2 Remove the bolt and nut. 3 Remove the roar spring. Installation 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications Suspension Strut / Shock Absorber: Specifications Front To Lower Arm Nuts 15 - 21 ft.lb To Frame Mounting Nut 30 - 41 ft.lb Rear Shock Absorber to Frame Nuts 17 ft.lb Shock Absorber Lower Bolt 46 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Solid Rear Axle Suspension Strut / Shock Absorber: Service and Repair Solid Rear Axle Special Service Tool(s) Removal WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing of an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. WARNING: The low pressure gas shock absorbers are charged with nitrogen gas 930 kPa (135 psi). Do not attempt to open, puncture, or apply heat to the shock absorbers. 1. Connect scan tool to the Data Link Connector (DLC). 2. Select the RIDE CONTROL OUTPUT screen and turn on the following solenoids to vent the entire system of air and to lower the vehicle to its lowest attainable height: ^ REAR FILL (rear fill solenoid). ^ GATEVALVE(gate solenoid[s]). ^ VENT (vent solenoid). 3. Raise and support the vehicle. 4. Remove the spare tire. 5. Use Hi-Lift Transmission Jack to support the rear axle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Solid Rear Axle > Page 7725 6. Remove the rear shock absorber electrical connector from the rear crossmember and disconnect the electrical connector. 7. Disconnect the air line from the shock absorber. ^ Compress the quick connect locking ring and pull out the air line. 8. Remove the shock absorber lower retaining nut and bolt and swing the shock absorber out of the lower mounting bracket. 9. Remove the attaching nuts on top of the rear crossmember and remove the shock absorber. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Solid Rear Axle > Page 7726 1. Note: When installing air lines make sure the white air line is fully inserted into the fitting for correct installation. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Solid Rear Axle > Page 7727 Suspension Strut / Shock Absorber: Service and Repair Independent Rear Suspension Shock Absorber and Spring Assembly Removal and Installation 1. Remove the wheel and tire assembly. 2. Remove and discard the nuts. 3. Remove the nut and the stabilizer bar link. ^ Discard the nut. 4. Remove the nut and the bolt. ^ Discard the nut. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Solid Rear Axle > Page 7728 5. Remove the bolt, flag nut and the shock absorber and spring as an assembly. ^ Discard the flag nut. 6. Using a suitable spring compressor, compress the spring until the tension is released from the shock absorber. 7. While holding the flats of the washer, remove the nut. ^ Remove the shock absorber. ^ Discard the nut. 8. Remove the washer, bushing and the upper mount. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Solid Rear Axle > Page 7729 9. Remove the insulator. 10. Remove the dust shield. 11. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Specifications Suspension Travel Bumper: Specifications Front Jounce Bumper to Frame Nut 18 - 26 ft.lb Rear Jounce Bumper Nut 15 - 21 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications Torsion Bar: Specifications Cover Plate Bolts 35 - 46 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications > Page 7736 Torsion Bar: Service and Repair Special Service Tool(s) Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs or shocks, which can result in shifting of the vehicle during these operations. Raise the vehicle on a hoist. 2. Remove the torsion bar cover plate. 1 Remove the torsion bar cover plate bolts. 2 Remove the torsion bar cover plate. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications > Page 7737 3. Note: Before relieving the torsion bar tension, measure and record the measurement of the torsion bar adjustment bolt. This measurement will be used as the preset depth for the new torsion bar adjustment bolt during installation. Make preliminary adjustment. ^ Measure and record the length where indicated. 4. Relieve the torsion bar tension. 1 Position the Torsion Bar Tool and adapters. 2 Tighten the Torsion Bar Tool until the torsion bar adjuster lifts off the adjustment bolt. 5. CAUTION: The torsion bar adjustment bolt is coated with: dry adhesive; and must be replaced if it is backed offer removed. Failure to do so can cause the adjustment bolt to loosen during operation and cause a loss of vehicle alignment. Remove the torsion bar adjustment bolt and nut. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications > Page 7738 6. Loosen the Torsion Bar Tool until the tension is removed from the torsion bar. 7. Remove the torsion bar. 1 Mark the torsion bar and the adjuster for proper installation. 2 Remove the torsion bar insulator. 3 Grasp the torsion bar, and pull it free from the front suspension lower arm. Installation 1. Position the torsion bar and the torsion bar adjuster. 2. Install the torsion bar adjuster. 1 Align the marks on the torsion bar and the torsion bar adjuster, then install the torsion bar adjuster. 2 Position the torsion bar insulator. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications > Page 7739 3. CAUTION: The torsion bar adjustment bolt is coated with: dry adhesive; and must be replaced if it is backed off or removed. Failure to do so can cause the adjustment bolt to loosen during operation and cause a loss of vehicle alignment. Preload the torsion bar. 1 Install the Torsion Bar Tool and the adapters. 2 Tighten the Torsion Bar Tool until the new adjustment bolt and nut can be installed. 3 Turn the adjustment bolt until the preliminary adjustment measurement (recorded length of the old adjustment bolt) is reached. 4. Install the torsion bar cover plate. 1 Position the torsion bar cover plate. 2 Install the torsion bar cover plate bolts. 5. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. 6. Adjust the ride height. 7. Check the alignment. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Lubricate the new rear wheel bearing. - For 4.0L SOHC and 4.0L EI with limited slip rear axles and 5.0L vehicles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - For 4.0L SOHC and 4.0L EI with conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check Wheel Bearing: Testing and Inspection Wheel Bearing Check 1. Raise and support the vehicle. ^ Make sure the system is warmed up to normal operating temperature, as thermal expansion can be the cause of a strain problem. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Spin the tire by hand to check the wheel bearings for roughness. NOTE: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. 3. Grip each front tire at the top and bottom arid move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check > Page 7745 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the service procedures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check > Page 7746 Wheel Bearing: Testing and Inspection Wheel Bearing Inspection 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the tire is off the floor. 2. Note: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel assembly. Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, perform one of the following actions. ^ On 4x2 vehicles, adjust the front wheel bearings. ^ On 4x4 vehicles, install a new wheel hub. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Solid Rear Axle Wheel Bearing: Service and Repair Solid Rear Axle Special Tools Special Tools Removal 1. Remove the axle shaft. 2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the rear wheel bearing and the inner wheel bearing oil seal at the same time. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Solid Rear Axle > Page 7749 Note: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and wheel bearing oil seal together. Installation 1. Lubricate the new rear wheel bearing. - For 4.0L SOHC and 4.0L EI with limited slip rear axles and 5.0L vehicles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - For 4.0L SOHC and 4.0L EI with conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Solid Rear Axle > Page 7750 Wheel Bearing: Service and Repair Independent Rear Suspension Wheel Bearing Removal And Installation 1. Remove the wheel knuckle. 2. CAUTION: Make sure that the press adapter outside diameter is slightly smaller than the hub outside diameter or damage to the knuckle will result. Using a suitable press, remove the hub from the bearing. - Discard the hub. 3. NOTE: The retainer ring is tapered and must be installed flat side down. Remove the retainer ring. - Discard the retainer ring. 4. Using a suitable press, remove the bearing from the wheel knuckle. - Discard the bearing. 5. CAUTION: The hub and bearing cannot be reused after disassembly. To install. reverse the removal Procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications - Tighten the spindle nut while rotating the brake disc and hub. - Loosen the spindle nut. - Tighten the spindle nut while rotating the brake disc and hub. - Install the following components: 1 Install the nut retainer. 2 Install the cotter pin. 3 Install the hub grease cap. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation JACKING WARNING: ^ THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE REAR JACK STORAGE AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. ^ DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. ^ MAKE SURE THE JACK AND JACK STANDS ARE PROPERLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. ^ WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK. Jacking Points - Front The front jacking point is a tab that extends from the lower control arm. Jacking Points - Rear 1. The rear jacking points are located on the rear axle tube. CAUTION: ^ Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to contact the cover at any point where the cover joins the housing. LIFTING Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 7759 Lifting Points Locate front hoist adapters and rear hoist adapters (top of frame arc) as indicated. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE REAR JACK STORAGE AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION: ^ Damage to the suspension, exhaust or steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement Technical Service Bulletin # 01B77 Date: 011001 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 7768 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 7769 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 7770 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 7771 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 7772 ^ 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 7773 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 7774 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 7775 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 7776 ^ 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 7777 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > NHTSA00V313000 > Oct > 00 > Recall 00V313000: Certification Label Non-Compliance Tires: Recalls Recall 00V313000: Certification Label Non-Compliance Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification." These vehicles were shipped from the assembly plant without Safety Certification Labels. Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash. Dealers will replace the certification labels. All vehicles were at dealerships and certification labels were affixed to these units on October 9, 2000. This recall is 100% complete. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 7786 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 7787 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 7788 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 7789 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 7790 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 7791 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 7792 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 7798 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 SOHC VIN K SFI (2001)) 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 7803 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 7804 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 7805 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 7806 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 SOHC VIN K SFI (2001)) 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 7807 ^ 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 SOHC VIN K SFI (2001)) 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 7808 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 SOHC VIN K SFI (2001)) 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 7809 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 SOHC VIN K SFI (2001)) 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 7810 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 SOHC VIN K SFI (2001)) 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 7811 ^ 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 SOHC VIN K SFI (2001)) 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 7812 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement Technical Service Bulletin # 00L12 Date: 010101 Information 00L12 SPECIAL FIELD ACTION All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement Original - January 2001 Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances Attachment III ^ Technical Information Customer Notification Letter Supplement # 1, February 5, 2001 - Updated Information All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement Supplement # 2, February 19, 2001 - Updated Information All 2001 Model Year Passenger Cars and light Trucks up to and Including F550 Super Duty Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement Special Field Action 00L12, Supplement # 1 dated 2/05/01 - Updated Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7817 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7818 Attachment I - Administrative Information OASIS Will not be active for this program. PLEASE NOTE Correct all units in dealer inventory prior to delivery to the customer. DEALER - OWNER CONTACT An owner list will not be provided for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACES II manual for claims preparation and submission information. Attachment II - Labor Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7819 LABOR ALLOWANCES Attachment III - Technical Information SPECIAL FIELD ACTION 00L12 WARRANTY GUIDE SUPPLEMENT VEHICLES COVERED BY THE NEW TIRE WARRANTY All 2001 model year passenger cars and light trucks up to and including F550 Super Duty vehicles sold in the U.S., U.S. Territories, Mexico, and Canada, built through December 31, 2000. NOTE: Information regarding tire warranty will be included in the Warranty Guide for vehicles produced after December 31, 2000. SERVICE PROCEDURE 1. Obtain a copy of the Warranty Guide Supplement. NOTE: Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make copies of the Warranty Guide Supplement (attached to this document). 2. Locate the vehicle Warranty Guide (located in the glove compartment). 3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle. PLEASE NOTE: This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a copy of the Warranty Guide Supplement with their notification letter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7820 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7821 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7822 Supplement # 1 - Information Supplement # 1, February 5, 2001 - Updated Information Cover Letter Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7823 Attachment III ^ Technical Information Customer Notification Letter Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7824 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7825 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7826 Supplement # 1 - Attachment I OASIS Will not be active for this program. PLEASE NOTE Correct all units in dealer inventory prior to delivery to the customer. DEALER - OWNER CONTACT An owner list will not be provided for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACES II manual for claims preparation and submission information. Supplement # 1 - Attachment II Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7827 LABOR ALLOWANCES Supplement # 1 - Attachment III WARRANTY GUIDE SUPPLEMENT NOTE: Information regarding tire warranty will be included in the Warranty Guide for vehicles produced after the end date listed above. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7828 SERVICE PROCEDURE 1. Obtain a copy of the Warranty Guide Supplement. NOTE: Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make copies of the Warranty Guide Supplement (included in this document). 2. Locate the vehicle Warranty Guide (located in the glove compartment). 3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle. PLEASE NOTE: This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a copy of the Warranty Guide Supplement with their notification letter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7829 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7830 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7831 Supplement # 2 - Information Supplement # 2, February 19, 2001 - Updated Information Cover Letter Dealer Letter Attachment I ^ Administrative Information Attachment II ^Labor Allowances Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7832 Attachment III ^ Technical Information Apology Letter Customer Notification Letter Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7833 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7834 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7835 Supplement # 2 - Attachment I OASIS Will not be active for this program. PLEASE NOTE Correct all units in dealer inventory prior to delivery to the customer. DEALER - OWNER CONTACT An owner list will not be provided for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACES II manual for claims preparation and submission information. Supplement # 2 - Attachment II Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7836 LABOR ALLOWANCES Supplement # 2 - Attachment III WARRANTY GUIDE SUPPLEMENT NOTE: Information regarding tire warranty will be included in the Warranty Guide for vehicles produced after the end date listed above. SERVICE PROCEDURE Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7837 1. Obtain a copy of the Warranty Guide Supplement. Note: Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make copies of the Warranty Guide Supplement (attached to this document). 2. Locate the vehicle Warranty Guide (located in the glove compartment). 3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle. PLEASE NOTE: This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a copy of the Warranty Guide Supplement with their notification letter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7838 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7839 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7840 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > NHTSA00V313000 > Oct > 00 > Recall 00V313000: Certification Label Non-Compliance Tires: All Technical Service Bulletins Recall 00V313000: Certification Label Non-Compliance Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification." These vehicles were shipped from the assembly plant without Safety Certification Labels. Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash. Dealers will replace the certification labels. All vehicles were at dealerships and certification labels were affixed to these units on October 9, 2000. This recall is 100% complete. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 SOHC VIN K SFI (2001)) 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 7849 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 7850 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 SOHC VIN K SFI (2001)) 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 7851 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 SOHC VIN K SFI (2001)) 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 7852 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 7853 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 7854 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 7855 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 7861 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement Technical Service Bulletin # 00L12 Date: 010101 Information 00L12 SPECIAL FIELD ACTION All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement Original - January 2001 Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances Attachment III ^ Technical Information Customer Notification Letter Supplement # 1, February 5, 2001 - Updated Information All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement Supplement # 2, February 19, 2001 - Updated Information All 2001 Model Year Passenger Cars and light Trucks up to and Including F550 Super Duty Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement Special Field Action 00L12, Supplement # 1 dated 2/05/01 - Updated Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7866 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7867 Attachment I - Administrative Information OASIS Will not be active for this program. PLEASE NOTE Correct all units in dealer inventory prior to delivery to the customer. DEALER - OWNER CONTACT An owner list will not be provided for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACES II manual for claims preparation and submission information. Attachment II - Labor Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7868 LABOR ALLOWANCES Attachment III - Technical Information SPECIAL FIELD ACTION 00L12 WARRANTY GUIDE SUPPLEMENT VEHICLES COVERED BY THE NEW TIRE WARRANTY All 2001 model year passenger cars and light trucks up to and including F550 Super Duty vehicles sold in the U.S., U.S. Territories, Mexico, and Canada, built through December 31, 2000. NOTE: Information regarding tire warranty will be included in the Warranty Guide for vehicles produced after December 31, 2000. SERVICE PROCEDURE 1. Obtain a copy of the Warranty Guide Supplement. NOTE: Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make copies of the Warranty Guide Supplement (attached to this document). 2. Locate the vehicle Warranty Guide (located in the glove compartment). 3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle. PLEASE NOTE: This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a copy of the Warranty Guide Supplement with their notification letter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7869 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7870 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7871 Supplement # 1 - Information Supplement # 1, February 5, 2001 - Updated Information Cover Letter Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7872 Attachment III ^ Technical Information Customer Notification Letter Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7873 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7874 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7875 Supplement # 1 - Attachment I OASIS Will not be active for this program. PLEASE NOTE Correct all units in dealer inventory prior to delivery to the customer. DEALER - OWNER CONTACT An owner list will not be provided for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACES II manual for claims preparation and submission information. Supplement # 1 - Attachment II Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7876 LABOR ALLOWANCES Supplement # 1 - Attachment III WARRANTY GUIDE SUPPLEMENT NOTE: Information regarding tire warranty will be included in the Warranty Guide for vehicles produced after the end date listed above. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7877 SERVICE PROCEDURE 1. Obtain a copy of the Warranty Guide Supplement. NOTE: Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make copies of the Warranty Guide Supplement (included in this document). 2. Locate the vehicle Warranty Guide (located in the glove compartment). 3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle. PLEASE NOTE: This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a copy of the Warranty Guide Supplement with their notification letter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7878 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7879 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7880 Supplement # 2 - Information Supplement # 2, February 19, 2001 - Updated Information Cover Letter Dealer Letter Attachment I ^ Administrative Information Attachment II ^Labor Allowances Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7881 Attachment III ^ Technical Information Apology Letter Customer Notification Letter Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7882 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7883 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7884 Supplement # 2 - Attachment I OASIS Will not be active for this program. PLEASE NOTE Correct all units in dealer inventory prior to delivery to the customer. DEALER - OWNER CONTACT An owner list will not be provided for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACES II manual for claims preparation and submission information. Supplement # 2 - Attachment II Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7885 LABOR ALLOWANCES Supplement # 2 - Attachment III WARRANTY GUIDE SUPPLEMENT NOTE: Information regarding tire warranty will be included in the Warranty Guide for vehicles produced after the end date listed above. SERVICE PROCEDURE Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7886 1. Obtain a copy of the Warranty Guide Supplement. Note: Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make copies of the Warranty Guide Supplement (attached to this document). 2. Locate the vehicle Warranty Guide (located in the glove compartment). 3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle. PLEASE NOTE: This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a copy of the Warranty Guide Supplement with their notification letter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7887 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7888 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 7889 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 7890 Tires: Specifications Tire Tread Depth P225/70R15 A/S 0.37 in P235/75R15 A/T 0.42 in P255/70R16 A/T 0.42 in Maximum Radial Runount Aluminum 0.040 in Steel 0.040 in Maximum Lateral Runout Aluminum 0.040 in Steel 0.040 in Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 7891 Tires: Service and Repair Removal 1. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel bearings. Note: To avoid damage or scratching to the center cap, place facing up when removed. Loosen the lug nuts. 1 Remove the center cap. 2 With the weight of the vehicle on the wheels, loosen the lug nuts. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 3. Raise and support the vehicle. 4. Remove the wheel and tire assembly. 1 Remove the lug nuts. 2 Remove the wheel and tire assembly, using a side-to-side rocking motion. Installation 1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. Clean the wheel hub mounting, surface and wheel pilot. 2. Install the tire and wheel assembly. 1 Position the tire and wheel assembly. 2 Install the lug trots hand-tight, then lower the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 7892 3. CAUTION: Failure to tighten the lug nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Tighten the lug nuts in a star pattern using a torque wrench or torque sticks. 4. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the center cap. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Recalls: > NHTSA00V313000 > Oct > 00 > Recall 00V313000: Certification Label Non-Compliance Wheels: Recalls Recall 00V313000: Certification Label Non-Compliance Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification." These vehicles were shipped from the assembly plant without Safety Certification Labels. Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash. Dealers will replace the certification labels. All vehicles were at dealerships and certification labels were affixed to these units on October 9, 2000. This recall is 100% complete. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 7906 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > NHTSA00V313000 > Oct > 00 > Recall 00V313000: Certification Label Non-Compliance Wheels: All Technical Service Bulletins Recall 00V313000: Certification Label Non-Compliance Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification." These vehicles were shipped from the assembly plant without Safety Certification Labels. Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash. Dealers will replace the certification labels. All vehicles were at dealerships and certification labels were affixed to these units on October 9, 2000. This recall is 100% complete. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 7916 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 7917 Wheels: Specifications Maximum Radial Runount Aluminum 0.045 in Steel 0.045 in Maximum Lateral Runout Aluminum 0.045 in Steel 0.045 in Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 7918 Wheels: Description and Operation WARNING: Do not mix different types of tires, such as radial, bias, or bias-belted, on the same vehicle except in emergencies. Vehicle handling can be seriously affected and can result in loss of control. Factory-installed tires and wheels are designed to operate satisfactorily with loads up to and including full-rated load capacity when inflated to recommended inflation pressures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel and Tire Wheels: Service and Repair Wheel and Tire Removal 1. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel bearings. Note: To avoid damage or scratching to the center cap, place facing up when removed. Loosen the lug nuts. 1 Remove the center cap. 2 With the weight of the vehicle on the wheels, loosen the lug nuts. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 3. Raise and support the vehicle. 4. Remove the wheel and tire assembly. 1 Remove the lug nuts. 2 Remove the wheel and tire assembly, using a side-to-side rocking motion. Installation 1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. Clean the wheel hub mounting, surface and wheel pilot. 2. Install the tire and wheel assembly. 1 Position the tire and wheel assembly. 2 Install the lug trots hand-tight, then lower the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel and Tire > Page 7921 3. CAUTION: Failure to tighten the lug nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Tighten the lug nuts in a star pattern using a torque wrench or torque sticks. 4. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the center cap. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel and Tire > Page 7922 Wheels: Service and Repair Wheel Leaks 1. Pinhole leaks in cast aluminum wheels compromise wheel integrity. Install a new wheel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Lubricate the new rear wheel bearing. - For 4.0L SOHC and 4.0L EI with limited slip rear axles and 5.0L vehicles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - For 4.0L SOHC and 4.0L EI with conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check Wheel Bearing: Testing and Inspection Wheel Bearing Check 1. Raise and support the vehicle. ^ Make sure the system is warmed up to normal operating temperature, as thermal expansion can be the cause of a strain problem. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Spin the tire by hand to check the wheel bearings for roughness. NOTE: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. 3. Grip each front tire at the top and bottom arid move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check > Page 7928 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the service procedures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Wheel Bearing Check > Page 7929 Wheel Bearing: Testing and Inspection Wheel Bearing Inspection 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the tire is off the floor. 2. Note: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel assembly. Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, perform one of the following actions. ^ On 4x2 vehicles, adjust the front wheel bearings. ^ On 4x4 vehicles, install a new wheel hub. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Solid Rear Axle Wheel Bearing: Service and Repair Solid Rear Axle Special Tools Special Tools Removal 1. Remove the axle shaft. 2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the rear wheel bearing and the inner wheel bearing oil seal at the same time. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Solid Rear Axle > Page 7932 Note: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and wheel bearing oil seal together. Installation 1. Lubricate the new rear wheel bearing. - For 4.0L SOHC and 4.0L EI with limited slip rear axles and 5.0L vehicles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - For 4.0L SOHC and 4.0L EI with conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Solid Rear Axle > Page 7933 Wheel Bearing: Service and Repair Independent Rear Suspension Wheel Bearing Removal And Installation 1. Remove the wheel knuckle. 2. CAUTION: Make sure that the press adapter outside diameter is slightly smaller than the hub outside diameter or damage to the knuckle will result. Using a suitable press, remove the hub from the bearing. - Discard the hub. 3. NOTE: The retainer ring is tapered and must be installed flat side down. Remove the retainer ring. - Discard the retainer ring. 4. Using a suitable press, remove the bearing from the wheel knuckle. - Discard the bearing. 5. CAUTION: The hub and bearing cannot be reused after disassembly. To install. reverse the removal Procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications - Tighten the spindle nut while rotating the brake disc and hub. - Loosen the spindle nut. - Tighten the spindle nut while rotating the brake disc and hub. - Install the following components: 1 Install the nut retainer. 2 Install the cotter pin. 3 Install the hub grease cap. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel Nuts 135 Nm (100 lb/ft) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front Removal 1. Raise the vehicle on a hoist. 2. Remove the wheel and tire assembly. 3. Remove the brake disc and hub. 4. Using a suitable press, remove the wheel stud from the brake disc and hub. Installation 1. Follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 7943 Wheel Fastener: Service and Repair Rear Special Tool(s) Special Service Tool(s) Removal CAUTION: Never use a hammer to remove the wheel stud. Damage to the axle flange, hub flange, wheel bearing or hub bearing can result. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air shocks, which can result in shifting of the vehicle curing these operations. Turn the air suspension service switch off, if so equipped. 2. Raise the vehicle and install safety stands. 3. Remove the wheel and tire assembly. 4. Remove the rear disc brake caliper, rear disc support bracket and brake disc if so equipped. Support the rear disc brake caliper with safety wire. 5. Using the C-Frame and Clamp Assembly Tool, press the wheel stud from its seat and discard. Installation CAUTION: Never use air tools to install wheel studs. The serrations can be stripped from the stud. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 7944 1. Insert a new wheel stud in the hole in the axle flange, making sure the serrations are aligned with those made by the original wheel stud. 2. Seat new wheel studs in axle flange. - Place four flat washers over the outside end of the wheel stud. - Thread a standard wheel nut with the flat side against the washers. - Tighten the wheel nut until the wheel stud head seats against the back side of the flange. 3. Remove the wheel nut and flat washers. 4. Install the brake disc, rear disc support bracket the rear disc brake caliper, if so equipped. 5. Install the wheel and tire assembly. 6. Lower the vehicle. 7. Turn the air suspension service switch on, if so equipped. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications Accumulator HVAC: Specifications Accumulator To Evaporator Core Fitting 35-42 Nm Suction/Accumulator Bracket Screws 6-8 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 7949 Accumulator HVAC: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 7950 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 7951 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 7952 Accumulator HVAC: Service Precautions CAUTION: Use a back-up wrench to prevent damage to the tubes. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 7953 Accumulator HVAC: Description and Operation NOTE: Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. The suction accumulator/drier is mounted to the A/C accumulator bracket to the right of the vehicle centerline. The inlet tube of the suction accumulator/drier attaches directly to the A/C evaporator core outlet tube and the outlet tube attaches to the A/C manifold and tube.After entering the inlet of the suction accumulator/drier, the heavier oil-laden refrigerant contacts an internally mounted dome (which serves as an umbrella) and drips down onto the bottom of the canister. - A small diameter oil bleed hole, in the bottom of the vapor return tube, allows the accumulated heavier liquid refrigerant and oil mixture to re-enter the compressor suction line at a controlled rate. As the heavier mixture passes through the small diameter liquid bleed hole, it has a second chance to vaporize and recirculate through the A/C compressor without causing compressor damage due to slugging. - A fine mesh screened filter fits tightly around the bottom of the vapor return tube to filter out refrigerant system contaminant particles. - A desiccant bag is mounted inside the canister to absorb any moisture which may be in the refrigerant system. - A fitting located on the top of the suction accumulator/drier is used to attach the A/C cycling switch. A long-travel Schrader-type valve stem core is installed in the fitting so that the A/C cycling switch can be removed without discharging the A/C system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 7954 Accumulator HVAC: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Perform the Refrigerant Discharging and Recovery Procedure. 3. Disconnect the A/C cycling switch electrical connector. 4. Disconnect the suction accumulator/drier to A/C evaporator core fitting. CAUTION: Use a back-up wrench to prevent damage to the tubes. 5. Disconnect the A/C manifold and tube spring lock coupling from the suction accumulator/drier suction accumulator/drier. 6. Remove the suction accumulator/drier. 1 Remove the screw from the mounting bracket. 2 Lift the suction accumulator/drier out. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 7955 7. Transfer the A/C cycling switch to the new suction accumulator/drier. INSTALLATION 1. To install, reverse the removal procedure. - Service the new suction accumulator/drier with the correct amount of PAG compressor oil, YN-12-C, F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. See: Refrigerant Oil Addition. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 7956 Accumulator HVAC: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool Set Disconnect Tool, Spring Lock Coupling Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Service and Repair Air Conditioning Switch: Service and Repair REMOVAL 1. Remove the climate control assembly. 2. Remove the heater blower motor switch. 1 Remove the screw. 2 Rotate and remove the heater blower motor switch. NOTE: The knob will come off when the switch is removed. 3. Remove the temperature control switch and the A/C damper door switch. 1 Remove the screw. 2 Rotate and remove the temperature control switch. 3 Rotate and remove the A/C damper door switch. NOTE: The knobs will come off when the switch is removed. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations Air Door Actuator / Motor: Locations Manual A/C Electrical Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 7964 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > With Manual A/C W/O EATC Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > With Manual A/C > Page 7967 W/EATC Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Page 7968 Air Door Actuator / Motor: Service Precautions CAUTION: Do Not attempt to bend any part of the lever. It is brittle and will break. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Page 7969 Air Door Actuator / Motor: Description and Operation The A/C electric blend door actuator is located on the plenum assembly. - its function is to move the air temperature blend door on command from the control assembly. - The A/C electric blend door actuator contains a reversible electric motor and a potentiometer. The potentiometer wiper is connected to the actuator output shaft and moves with the output shaft to indicate the position of the air temperature blend door. - A 5 volt signal is applied to the ends of the potentiometer. The voltage available at the wiper indicates the position of the potentiometer. The expressed value of the actuator wiper voltage is sent to the electronic automatic temperature control module and is matched with the wiper voltage of the module potentiometer. The control module then drives the actuator motor in whichever direction is necessary to make the actuator wiper voltage agree with the control module wiper voltage. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Motor Air Door Actuator / Motor: Service and Repair Blend Door Motor REMOVAL 1. Remove the instrument panel. Refer to: " Body and Frame : Interior Trim : Dashboard/Instrument Panel : Service and Repair " See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 2. Remove the A/C electronic door actuator motor. - Remove the screws. - Disconnect the harness connector and remove the A/C electronic door actuator motor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Motor > Page 7972 Air Door Actuator / Motor: Service and Repair Air Door Actuator / Motor, HVAC Air Inlet Duct Door Vacuum Control Motor REMOVAL 1. Release the stops and lower the glove compartment door to the floor. 2. Remove the screws and disconnect the vacuum hose. 3. Rotate the vacuum control motor. CAUTION: Do not attempt to bend any part of the lever. It is brittle and will break. INSTALLATION 1. To install, reverse the removal procedure. Panel/Defrost Door Vacuum Control Motor REMOVAL Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Motor > Page 7973 1. Remove the screws and disconnect the vacuum hose. 2. Rotate the vacuum control motor, disengage the lever, and remove the vacuum control motor. CAUTION: Do not attempt to bend any part of the lever. It is brittle and will break. INSTALLATION 1. To install, reverse the removal procedure. Panel/Floor Door Vacuum Control Motor REMOVAL 1. Remove the screws and disconnect the vacuum hose. 2. Rotate the vacuum control motor, disengage the lever, and remove the vacuum control motor. CAUTION: Do Not attempt to bend any part of the lever. It is brittle and will break. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Motor > Page 7974 INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Specifications Air Duct: Specifications Side Window Demister Hose And Nozzle Screws 2-3 Nm Windshield Defroster Hose Nozzle Screws 2-3 Nm Rear Floor Duct Screws 2-3 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Specifications > Page 7978 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor Duct Air Duct: Service and Repair Floor Duct REMOVAL 1. Remove the console rear controls. 2. Remove the rear floor duct. 1. Remove the screws. 2. Remove the rear floor duct. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor Duct > Page 7981 Air Duct: Service and Repair Windshield Defroster and Side Window Demister Nozzle REMOVAL 1. Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 2. Remove the two screws and remove the LH demister nozzle and duct. 3. Remove the two screws and remove the RH demister nozzle and duct. 4. Remove the screws and remove the windshield defroster hose nozzle. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor Duct > Page 7982 1. Follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Specifications Air Register: Specifications LH Instrument Panel Register Screws 3.4-4.8 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defrost Nozzles and Side Demister Air Register: Service and Repair Defrost Nozzles and Side Demister REMOVAL 1. Remove the instrument panel. Refer to: " Body and Frame : Interior Trim : Dashboard/Instrument Panel : Service and Repair " See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 2. Remove the two screws and remove the LH demister nozzle and duct. 3. Remove the two screws and remove the RH demister nozzle and duct. 4. Remove the screws and remove the windshield defroster hose nozzle. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defrost Nozzles and Side Demister > Page 7988 1. Follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defrost Nozzles and Side Demister > Page 7989 Air Register: Service and Repair Air Register Center Radio Removing Tool SPECIAL SERVICE TOOL(S) REMOVAL 1. Use the Radio Removing Tool to remove the radio chassis. 2. Disconnect the antenna lead and the wire harness connectors. 3. Remove the instrument panel finish panel. 1 Remove the screws. 2 Disengage the spring clips and remove the instrument panel finish panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defrost Nozzles and Side Demister > Page 7990 4. Disconnect the wire harness connector. 5. Release the eight clips and remove the center instrument panel register from the instrument panel finish panel. INSTALLATION 1. Follow the removal procedure in reverse order. Driver Side REMOVAL 1. Remove the LH instrument panel finish panel; refer to Dash Board. 2. Remove the LH instrument panel register. 1 Remove the screws. 2 Remove the LH instrument panel register. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defrost Nozzles and Side Demister > Page 7991 INSTALLATION 1. Follow the removal procedure in reverse order. Passenger Side REMOVAL 1. Lift the edge of the RH instrument panel register to expose the retainers. 2. Release the retainers and remove the RH instrument panel register. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Page 7992 Radio Removing Tool Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7996 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7997 Ambient Temperature Sensor / Switch HVAC: Description and Operation The A/C ambient air temperature sensor and bracket: - is located in front of the A/C condenser core near the center of the vehicle. - contains a thermistor which measures the temperature of outside air as a resistance and sends that reading to the electronic automatic temperature control assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations Blower Motor: Locations Manual A/C Electrical Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Page 8001 Electronic Automatic Temperature Control Electrical Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Page 8002 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Page 8003 Blower Motor: Description and Operation The A/C blower motor pulls air from the air inlet and forces it into the plenum assembly where it is mixed and distributed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Page 8004 Blower Motor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the speed control servo. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Position the speed control servo aside. 3. Position the coolant/washer reservoir. 1 Remove the screws and the nuts. 2 Move the coolant/washer reservoir aside. 4. Remove the blower motor. 1 Disconnect the vent hose. 2 Disconnect the electrical connector. 3 Remove the four screws. 4 Remove the blower motor. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Page 8005 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Blower Motor Relay Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 8010 Electronic Automatic Temperature Control Electrical Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 8011 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 8012 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 8013 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 8014 Blower Motor Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations Blower Motor Resistor: Locations Manual A/C Electrical Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 8018 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 8019 Blower Motor Resistor: Description and Operation The heater blower motor switch resistor has the following features: - The assembly is located on the evaporator housing in the engine compartment. - Three resistance elements are mounted on the resistor board to provide four blower motor speeds. - Depending on the heater blower motor switch position, series resistance is added or bypassed in the blower motor circuit to decrease or increase blower motor speed. - An overheating protective device (thermal limiter) will open the resistor coil circuit when the temperature reaches 121°C (250°F) interrupting the blower motor operation in all speeds except HIGH. - The thermal limiter cannot be reset and is not serviceable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair NOTE: The air distribution system of this vehicle cannot be equipped with a cabin air filter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 8029 Cabin Temperature Sensor / Switch: Description and Operation The in-car temperature sensor operates in the following manner: - A thermistor in the in-car temperature sensor measures air temperature inside the passenger compartment. - An automatic temperature control sensor hose and elbow is connected between the plenum assembly and the in-car temperature sensor. - The automatic temperature control sensor hose and elbow takes air from the plenum assembly air stream to create a suction in the in-car temperature sensor. - The suction draws in-vehicle air into the in-car temperature sensor and across the thermistor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications Air Gap Between Pulley And Hub 0.35-0.85 mm A/C Clutch Bolt 11-14 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8034 Compressor Clutch: Service Precautions CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8035 Compressor Clutch: Description and Operation NOTE: - Internal A/C compressor components are not serviced separately. The FS-10 A/C compressor is serviced only as an assembly. The A/C clutch, A/C clutch pulley, A/C clutch field coil and the shaft seal are serviceable. - Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. Compressor Clutch Components The magnetic A/C clutch has the following characteristics: - It drives the compressor shaft. - When battery positive voltage (B+) is applied to the A/C clutch field coil, the clutch disc and hub assembly is drawn toward the A/C clutch pulley. - The magnetic force locks the clutch disc and hub assembly and the A/C clutch pulley together as one unit, causing the compressor shaft to rotate. - When B+ is removed from the A/C clutch field coil, springs in the clutch disc and hub assembly move the clutch plate away from the A/C clutch pulley. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8036 Compressor Clutch: Adjustments 1. Check the A/C clutch air gap at three equally spaced places between the clutch hub and the A/C clutch pulley. 2. Remove the A/C clutch. Add or remove spacers between the A/C clutch and the compressor shaft until clearance is within specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8037 Compressor Clutch: Service and Repair SPECIAL SERVICE TOOL(S) REMOVAL 1. Remove the A/C compressor. 2. Remove the bolt. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8038 1 Hold the A/C clutch hub with the Compressor Clutch Holding Tool. 2 Remove the bolt. 3. Remove the A/C clutch and the A/C clutch hub spacer. 1 Thread an 8 x 1.25 mm bolt into the A/C clutch to force it from the compressor shaft. 2 Lift the A/C clutch and the A/C clutch hub spacer from the compressor shaft. 4. Remove the pulley snap ring. 5. Remove the A/C clutch pulley. 6. Remove the A/C clutch field coil. 1 Note the location of the A/C clutch field coil electrical connector. 2 Install the Field Coil Remover on the nose opening of the A/C compressor. 3 Install the Puller-Differential Side Bearing. 4 Remove the A/C clutch field coil. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8039 CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. INSTALLATION 1. Clean the A/C clutch field coil and pulley bearing mounting surfaces. 2. Install the A/C clutch field coil. 1 Place the A/C clutch field coil on the A/C compressor with the A/C clutch field coil electrical connector properly positioned. 2 Place the Field Coil Replacer on the A/C clutch field coil. 3 Place the Coil Replacer on the Field Coil Replacer. 4 Use the 2-Jaw Puller to install the A/C clutch field coil until bottomed completely against the A/C compressor. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. 3. Install the A/C clutch pulley. NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head; it must be correctly aligned during installation. 4. Install the pulley snap ring with the bevel side out. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8040 5. Place one nominal thickness A/C clutch hub spacer inside the clutch hub spline opening. 6. Install the A/C clutch. 7. Install the bolt. 1 Hold the A/C clutch hub with the Compressor Clutch Holding Tool. 2 Tighten the bolt. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8041 Compressor Clutch Components 8. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. 9. Install the A/C compressor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 8042 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Locations Electronic Automatic Temperature Control Electrical Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions Compressor Shaft Seal: Service Precautions CAUTION: Do not allow dirt or other foreign materials to enter the A/C compressor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 8049 Compressor Shaft Seal: Service and Repair SPECIAL SERVICE TOOL(S) REMOVAL 1. Remove the A/C clutch from the A/C compressor. 2. Remove the shaft seal felt from the nose of the A/C compressor with the O-Ring Removal Pick. 3. Clean the compressor nose area. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 8050 4. Insert the tip of the Snap Ring Remover into one of the snap ring eyes. 5. Rotate the Snap Ring Remover to position the tool tip and the snap ring eye closest to the A/C compressor shaft. 6. Pull the Snap Ring Remover up quickly while keeping the tool shaft against the side of the nose opening and remove the snap ring. 7. Engage the Compressor Seal Remover into the inside diameter of the shaft seal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 8051 8. Turn the tool handle clockwise to expand the tool tip inside of the shaft seal. 9. Pull the seal from the A/C compressor. INSTALLATION 1. Clean the A/C compressor nose area. CAUTION: Do not allow dirt or other foreign materials to enter the A/C compressor. 2. Place the shaft seal on the seal protector. Lubricate the shaft seal and protector with PAG compressor oil, YN-12-C, F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. 3. Position the shaft seal and the Seal Protector over the A/C compressor shaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 8052 4. Push the shaft seal onto the A/C compressor shaft with the Shaft Seal Replacer until seated. 5. Install the shaft seal snap ring. 6. Conduct the A/C compressor external leak test. 7. Install the shaft seal felt. 8. Install the A/C clutch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 8053 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Compressor Clutch Relay Compressor Clutch Relay: Locations Compressor Clutch Relay Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Compressor Clutch Relay > Page 8058 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Compressor Clutch Relay > Page 8059 Compressor Clutch Relay: Locations Compressor Cut-Off Relay Manual A/C Electrical Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Compressor Clutch Relay > Page 8060 Electronic Automatic Temperature Control Electrical Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 8061 Compressor Clutch Relay: Description and Operation WIDE OPEN THROTTLE A/C CUT-OFF The Wide Open Throttle A/C Cut-Off Relay (may be referred to as the A/C clutch relay) is normally open. There is no direct electrical connection between the A/C switch or EATC Module and the A/C clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACP (SW), A/C Cycling Switch (ACCS)). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine rpm, throttle position), the PCM will ground the Wide Open Throttle A/C (WAC) output, closing the relay contacts and sending voltage to the A/C clutch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 8062 Compressor Clutch Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications Compressor Fitting HVAC: Specifications A/C Manifold Tube Bolt 17-23 Nm A/C Manifold To Generator Clamp Nut 15-22 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 8066 Refrigeration System Components - 4.0L (5.0L Similar) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 8067 Compressor Fitting HVAC: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Perform the Refrigerant Discharging and Recovery Procedure. 3. Disconnect the A/C pressure cut-off switch connector. 4. Disconnect the A/C manifold and tube from the A/C condenser core. 5. Disconnect the A/C manifold and tube from the suction accumulator/drier. 6. Remove the bolt. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 8068 7. Remove the nut. 8. Lift the A/C manifold and tube out of the vehicle. INSTALLATION 1. To install, reverse the removal procedure. - Lubricate the new O-ring seals with PAG Compressor Oil, YN-12-C, F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 8069 Compressor Fitting HVAC: Tools and Equipment Spring Lock Coupling Disconnect Tool (5/8 Inch) Disconnect Tool, Spring Lock Coupling Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 8070 Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications Condenser HVAC: Specifications A/C Line To Condenser Nut 6.8-9.2 Nm A/C Condenser Core Bolt 8.4-11.2 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8074 Condenser HVAC: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8075 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8076 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8077 Condenser HVAC: Service Precautions CAUTION: Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8078 Condenser HVAC: Description and Operation NOTE: Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. The A/C condenser core has the following characteristics: - It is an aluminum fin and tube design heat exchanger located in front of the vehicle radiator. - It cools compressed refrigerant gas by allowing air to pass over fins and tubes to extract heat and by condensing gas to liquid refrigerant as it is cooled. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8079 Condenser HVAC: Testing and Inspection On-Vehicle Leak Test 1. Perform the Refrigerant Discharging and Recovery Procedure. See: Service and Repair/Refrigerant Discharging and Recovery procedure 2. Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the core tubes. 3. Clean the spring lock couplings. For additional information, refer to Spring Lock Coupling. See: Coupler HVAC/Service and Repair/Spring Lock Coupling Connect and Disconnect Procedure 4. Connect the appropriate test fittings from the R-12/R-134a Air Conditioning Test Fitting Set to the evaporator or condenser tube connections. 5. Connect the red and blue hoses from the R-134a Manifold (gauge Set to the test fittings on the A/C evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum pump. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to the test fittings. if available, use hoses without shut-off valves. If hoses with shut-off valves are used, make 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 shut-off valve does not open. 6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low pressure gauge indicates 101 kPa (30 in-Hg). The 45 minute evacuation is necessary to remove any refrigerant from oil left in the A/C evaporator core or A/C condenser core. If the refrigerant is not completely removed from the oil, outgassing will degrade the vacuum and appear as a refrigerant leak. 7. If the low pressure gauge reading will not drop to 101 kPa (30 in-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 installing a new A/C evaporator core or A/C condenser core. 8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump. Observe the low pressure gauge; it should remain at the 101 kPa (30 in-Hg) mark. If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101 kPa (30 in-Hg) 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 gauge valves open for an additional 30 minutes to remove any remaining refrigerant from the oil in the A/C evaporator core or A/C condenser core. Then recheck for loss of vacuum. - If a very small leak is suspected, allow the system to set overnight with vacuum applied and check for vacuum loss. 9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure, install a new A/C evaporator core or A/C condenser core. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8080 Condenser HVAC: Service and Repair REMOVAL CAUTION: Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. NOTE: If an A/C condenser core leak is suspected, the A/C condenser core must be leak tested before it is removed from the vehicle. 1. Perform the Refrigerant Discharging and Recovery Procedure. 2. Disconnect the A/C manifold and tube and the condenser to evaporator tube from the A/C condenser core. 3. Remove the radiator. For additional information, refer to Cooling System. 4. Remove the condenser core bolt. 5. Squeeze to release the buckle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8081 6. Slide the A/C condenser out of the locators. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8082 1. To install, reverse the removal procedure. - Service the replacement A/C condenser core with the correct amount of PAG compressor oil, YN-12-C, F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. See: Refrigerant Oil Addition. - Lubricate new O-ring seals with PAG compressor oil, YN-12-C, F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. NOTE: When a new A/C condenser is installed, a new A/C evaporator core orifice should also be installed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8083 Condenser HVAC: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool Set Disconnect Tool, Spring Lock Coupling Heater Hose Disconnect Tool Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 8084 Special Tool(s) Set, A/C Fittings Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations Control Assembly: Locations Manual A/C Electrical Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 8088 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 8089 Control Assembly: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 8090 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > With Electronic Automatic Temperature Control (EATC) Control Assembly: Description and Operation With Electronic Automatic Temperature Control (EATC) The Electronic Automatic Temperature Control (EATC) module, located in the instrument panel, has the following features: - 11 push buttons. - a blower speed override thumbwheel for manual input. - a vacuum fluorescent display for displaying set temperature, function and Diagnostic Trouble Codes (DTCs). - an On-Board Diagnostic (OBD) feature to supply the technician with Diagnostic Trouble Codes (DTCs). These DTCs direct the technician to the inoperative component. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > With Electronic Automatic Temperature Control (EATC) > Page 8093 Control Assembly: Description and Operation With Manual A/C The climate control assembly has three system controls: - The A/C heater function selector switch combines a vacuum selector valve with two electrical switches to supply battery positive voltage (B+) to the A/C clutch circuit and the blower motor control circuit. - The temperature selection is accomplished with a potentiometer connected to the electric blend door actuator that controls positioning of the temperature blend door. Movement of the control knob from COOL (blue) to WARM (red) causes a corresponding movement on the air temperature control door and determines the temperature that the system will maintain. - The blower motor switch controls blower motor speed by adding or bypassing resistors in the heater blower motor switch resistor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Page 8094 Control Assembly: Testing and Inspection For further information regarding this component please refer to : Heating and Air Conditioning; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > With Electronic Automatic Temperature Control Control Assembly: Service and Repair With Electronic Automatic Temperature Control REMOVAL 1. Remove the radio chassis. 2. Remove the instrument panel finish panel. 1 Remove the screws. 2 Disengage the spring clips and remove the instrument panel finish panel. 3. Disconnect the connectors. 4. Remove the screws and remove the electronic automatic temperature control module. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > With Electronic Automatic Temperature Control > Page 8097 5. Remove the electronic automatic temperature control module. 1 Disconnect the electrical connectors. 2 Remove the nuts. 3 Disconnect the vacuum harness connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > With Electronic Automatic Temperature Control > Page 8098 Control Assembly: Service and Repair Control Assembly Bulbs REMOVAL 1. Remove the climate control assembly. 2. Turn and pull the lamp socket. - Install a new the bulb in the socket. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > With Electronic Automatic Temperature Control > Page 8099 Control Assembly: Service and Repair With Manual Climate Control REMOVAL 1. Remove the radio chassis. For additional information, refer to Radio,Stereo and Compact disc. 2. Remove the instrument panel finish panel. 1 Remove the screws. 2 Disengage the spring clips and remove the instrument panel finish panel. 3. Disconnect the connectors. 4. Remove the screws and remove the climate control assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > With Electronic Automatic Temperature Control > Page 8100 5. Disconnect the climate control assembly. 1 Disconnect the electrical connectors. 2 Disconnect the vacuum harness connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From Floor Ducts Control Module HVAC: Customer Interest A/C - Cold Air Blows From Floor Ducts Article No. 02-8-5 04/29/02 CLIMATE CONTROL - ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC) BLOWS COLD AIR FROM FLOOR DUCTS - VEHICLES PRODUCED BEFORE 9/30/2000 ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles produced before 9/30/2000 equipped with Electronic Automatic Temperature Control (EATC) may blow cold air from the floor ducts after the climate control system reaches a steady state in AUTO mode after switching from the FLOOR/DEFROST mode position to the FLOOR mode position, usually after driving for 15-30 minutes. This may be caused by the software version of the EATC Module. ACTION Update the software version or replace the EATC Module. Refer to the following Service Procedure for details. SERVICE PROCEDURE On vehicles equipped with the following EATC modules, F87H-18C612-BD, F87H-18C612-BE, XL2H-18C612-AA, or XL2H-18C612-AB, use NGS with Service Card Version 9.0 or later to update the EATC module software. On all other modules, replace the EATC module with service part YL2Z-19980-AA. Refer to section 412-04 of the appropriate model year Workshop Manual for removal and installation procedures. Use NGS with diagnostic card installed to verify the EATC module ID number (Engineering Part Number). NGS Procedure for Identifying EATC Module ID Number 1. Select "Diagnostics". 2. Select "EATC". 3. Select "Module I.D". NGS will display the EATC module I.D. number (Engineering Part Number). Vehicles that have been previously updated with this software will display "GO7H-BA". NGS Procedure for Updating Software 1. Select "Service Bay Functions". 2. Select "EATC" from module list. 3. Select "Module Configuration". 4. Select "99-01 Explorer" or "99-01 Mountaineer". Upon completion of the software upgrade, NGS will change the EATC module I.D to G07H-BA and display "Module Data Download Successfull". If the EATC module has been updated previously, or the module is not one of the modules listed as being capable of being updated, NGS will display "Can not update with the NGS". If the module is not capable of being updated, replace the module with part number YL2Z-19980-AA as listed above. Parts Block Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From Floor Ducts > Page 8109 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208300, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From Floor Ducts Control Module HVAC: All Technical Service Bulletins A/C - Cold Air Blows From Floor Ducts Article No. 02-8-5 04/29/02 CLIMATE CONTROL - ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC) BLOWS COLD AIR FROM FLOOR DUCTS - VEHICLES PRODUCED BEFORE 9/30/2000 ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles produced before 9/30/2000 equipped with Electronic Automatic Temperature Control (EATC) may blow cold air from the floor ducts after the climate control system reaches a steady state in AUTO mode after switching from the FLOOR/DEFROST mode position to the FLOOR mode position, usually after driving for 15-30 minutes. This may be caused by the software version of the EATC Module. ACTION Update the software version or replace the EATC Module. Refer to the following Service Procedure for details. SERVICE PROCEDURE On vehicles equipped with the following EATC modules, F87H-18C612-BD, F87H-18C612-BE, XL2H-18C612-AA, or XL2H-18C612-AB, use NGS with Service Card Version 9.0 or later to update the EATC module software. On all other modules, replace the EATC module with service part YL2Z-19980-AA. Refer to section 412-04 of the appropriate model year Workshop Manual for removal and installation procedures. Use NGS with diagnostic card installed to verify the EATC module ID number (Engineering Part Number). NGS Procedure for Identifying EATC Module ID Number 1. Select "Diagnostics". 2. Select "EATC". 3. Select "Module I.D". NGS will display the EATC module I.D. number (Engineering Part Number). Vehicles that have been previously updated with this software will display "GO7H-BA". NGS Procedure for Updating Software 1. Select "Service Bay Functions". 2. Select "EATC" from module list. 3. Select "Module Configuration". 4. Select "99-01 Explorer" or "99-01 Mountaineer". Upon completion of the software upgrade, NGS will change the EATC module I.D to G07H-BA and display "Module Data Download Successfull". If the EATC module has been updated previously, or the module is not one of the modules listed as being capable of being updated, NGS will display "Can not update with the NGS". If the module is not capable of being updated, replace the module with part number YL2Z-19980-AA as listed above. Parts Block Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From Floor Ducts > Page 8115 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208300, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control Blower Control Service Tips Control Module HVAC: All Technical Service Bulletins Climate Control - Blower Control Service Tips Article No. 00-21-3 10/16/00 CLIMATE CONTROL - EATC - BLOWER MOTOR CONTROL SERVICE TIPS FORD: 1990-1993 THUNDERBIRD 1990-2001 CROWN VICTORIA 1995-2001 EXPLORER LINCOLN: 1990-2001 TOWN CAR 2000-2001 LS MERCURY: 1990-1993 COUGAR 1990-2001 GRAND MARQUIS 1997-2001 MOUNTAINEER ISSUE The following service procedure has been developed to aid technicians in diagnosing EATC/DATC system blower motor control concerns. ACTION Refer to the following Service Procedure as an aid in helping diagnose blower motor control concerns. SERVICE PROCEDURE 1. Check blower motor operation in all speeds. ^ If the blower motor does not operate in any speed, refer to Step 2. ^ If the blower motor continuously operates in HIGH, refer to the appropriate pinpoint test in the Service/Workshop Manual. ^ If the blower motor does not operate in HIGH speed, refer to Step 3. ^ If the blower motor does not operate at speeds other than HIGH, refer to Step 4. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control Blower Control Service Tips > Page 8120 NOTE: REFER TO FIGURE 1 FOR CONNECTOR VIEW. 2. Refer to the appropriate pinpoint test in the Service/Workshop Manual, except for checking the EATC/DATC module. When checking the EATC/DATC module, set the blower motor speed to HIGH blower and measure the voltage between the blower motor high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is 5 ohms or less, repair the circuit. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). Retest the system for normal operation. 3. Set the blower speed control to HIGH and measure the voltage between the blower motor control high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. 4. Set the blower speed control to any speed other than HIGH and measure the voltage between the blower motor control blower control circuit (Pin 2 at the controller) and ground at the EATC/DATC module. a. If the voltage is below 1 volt, measure the resistance between the blower motor speed controller connector Pin 1 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. b. If the voltage is between 1 and 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 2 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. c. If the voltage is greater than 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 1 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less; install a new blower motor speed controller (19E624). If. the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control Blower Control Service Tips > Page 8121 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208300, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control - Blower Control Service Tips Control Module HVAC: All Technical Service Bulletins Climate Control - Blower Control Service Tips Article No. 00-21-3 10/16/00 CLIMATE CONTROL - EATC - BLOWER MOTOR CONTROL SERVICE TIPS FORD: 1990-1993 THUNDERBIRD 1990-2001 CROWN VICTORIA 1995-2001 EXPLORER LINCOLN: 1990-2001 TOWN CAR 2000-2001 LS MERCURY: 1990-1993 COUGAR 1990-2001 GRAND MARQUIS 1997-2001 MOUNTAINEER ISSUE The following service procedure has been developed to aid technicians in diagnosing EATC/DATC system blower motor control concerns. ACTION Refer to the following Service Procedure as an aid in helping diagnose blower motor control concerns. SERVICE PROCEDURE 1. Check blower motor operation in all speeds. ^ If the blower motor does not operate in any speed, refer to Step 2. ^ If the blower motor continuously operates in HIGH, refer to the appropriate pinpoint test in the Service/Workshop Manual. ^ If the blower motor does not operate in HIGH speed, refer to Step 3. ^ If the blower motor does not operate at speeds other than HIGH, refer to Step 4. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control - Blower Control Service Tips > Page 8127 NOTE: REFER TO FIGURE 1 FOR CONNECTOR VIEW. 2. Refer to the appropriate pinpoint test in the Service/Workshop Manual, except for checking the EATC/DATC module. When checking the EATC/DATC module, set the blower motor speed to HIGH blower and measure the voltage between the blower motor high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is 5 ohms or less, repair the circuit. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). Retest the system for normal operation. 3. Set the blower speed control to HIGH and measure the voltage between the blower motor control high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. 4. Set the blower speed control to any speed other than HIGH and measure the voltage between the blower motor control blower control circuit (Pin 2 at the controller) and ground at the EATC/DATC module. a. If the voltage is below 1 volt, measure the resistance between the blower motor speed controller connector Pin 1 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. b. If the voltage is between 1 and 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 2 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. c. If the voltage is greater than 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 1 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less; install a new blower motor speed controller (19E624). If. the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control - Blower Control Service Tips > Page 8128 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208300, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 8131 Control Module HVAC: Locations Blower Motor Speed Control Electronic Automatic Temperature Control Electrical Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 8132 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Electronic Climate Control Module Control Module HVAC: Diagrams Electronic Climate Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Electronic Climate Control Module > Page 8135 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Page 8136 Control Module HVAC: Description and Operation The blower speed control is located on the evaporator housing in the engine compartment. - The function of the blower motor speed control is to convert low power signals from the electronic automatic temperature control module to a high current, variable ground feed for the blower motor. - The blower motor speed is infinitely variable and is controlled by the electronic automatic temperature control module software. - A delay function provides a gradual increase or decrease in blower motor speed under all conditions. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Peanut Fitting Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Peanut Fitting > Page 8141 Spring Lock Coupling Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Page 8142 Coupler HVAC: Service Precautions CAUTION: - Do not use metal tools to remove the O-ring seals. They can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks. - Do not use a screwdriver or similar tool to remove the A/C tube lock coupling spring ; this can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks. - Maintain low speed drill rotation when inserting or removing the cleaning tool to prevent axial scratches which may cause future leaks. - Use only new green O-ring seals. The use of any O-ring seals other than specified may result in intermittent leakage during vehicle operation. - Support the female fitting with a wrench to prevent the tubes from twisting. - Do not use metal tools to remove the O-ring seal. They can cause axial scratches across the O-ring seal groove resulting in refrigerant leaks. - Use only new green O-ring seals. The use of any O-ring seals other than specified may result in intermittent leakage during vehicle operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and Operation > Spring Lock Coupling Coupler HVAC: Description and Operation Spring Lock Coupling Spring Lock Coupling The spring lock coupling is a refrigerant 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 then prevent the flared end of the female fitting from pulling out of the cage. - Three O-ring seals are used to seal between the two halves of the A/C condenser core couplings, all other couplings have two O-ring seals. - These O-ring seals are green in color and are made of special material. - Use only the green O-ring seals listed in the Ford Master Parts Catalog for the spring lock coupling. - A plastic indicator ring is used on the spring lock couplings of the A/C evaporator core to indicate, during vehicle assembly, that the coupling is connected. Once the coupling is connected, the indicator ring is no longer necessary but will remain captive by the coupling near the cage opening. - The indicator ring may also be used during service operations to indicate connection of the coupling. - An A/C tube lock coupling clip may be used to secure the coupling but is not required. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and Operation > Spring Lock Coupling > Page 8145 Coupler HVAC: Description and Operation Peanut Fitting The A/C condenser core uses the peanut shaped refrigerant fittings instead of spring lock couplings. - The male and female blocks of the peanut fitting are retained with a nut. - An O-ring seal is installed around the tube on the male block. - The female block is welded to the tube and is not adjustable. - Support the female fitting with a wrench to prevent twisting of the tubes. - The male block will pivot around the tube to allow for alignment with the female block during assembly. - When correctly assembled the male and female fittings should be flush. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure Coupler HVAC: Service and Repair Spring Lock Coupling Connect and Disconnect Procedure Spring Lock Coupling SPECIAL SERVICE TOOL(S) DISCONNECT 1. Remove the A/C tube lock coupling clip. 2. Fit the spring lock coupling disconnect tool to the spring lock coupling. 3. Push the tool into the cage opening to release the female fitting from the A/C tube lock coupling spring. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure > Page 8148 4. Pull the spring lock coupling fittings apart. 5. Remove the O-ring seals with a non-metallic tool. - There are three O-ring seals required for the A/C condenser core couplings. - There are two O-ring seals for all other refrigerant tube couplings. CAUTION: Do not use metal tools to remove the O-ring seals. They can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks. 6. Remove the A/C tube lock coupling spring with a small hooked wire. CAUTION: Do not use a screwdriver or similar tool to remove the A/C tube lock coupling spring ; this can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks. CLEANING 1. Fabricate a cleaning tool from a 1/8 inch diameter brazing rod. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure > Page 8149 2. Cut an abrasive pad from maroon colored 3M Scotch Brite(R) with the dimensions corresponding to the coupling size. 3. Assemble the pad to the tool. 4. Coat the abrasive pad with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. 5. Roll the pad on the tool and install it in a variable speed drill motor. 6. Polish for one minute at moderate speed (less than 1,500 rpm) or until the surface is clean and free of scratches or foreign material. CAUTION: Maintain low speed drill rotation when inserting or removing the cleaning tool to prevent axial scratches which may cause future leaks. 7. Clean the fitting with a lint-free cloth. 8. Inspect the surface for grooves or scratches. If grooves and scratches are still present, install a new component. 9. Clean the O-ring seal grooves with a 300 mm (12 inch) length of natural fiber string. - Loop the string around the grooves and pull the string back and forth. 10. Remove any foreign material from the grooves with a lint-free cloth. CONNECT Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure > Page 8150 1. Install the A/C tube lock coupling spring. 2. Lubricate the inside of the coupling with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-l2-C) or equivalent meeting Ford specification WSH-MlC231-B. 3. Install the O-ring seals. - Lubricate the O-ring seals with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSR-M1C231-B. CAUTION: Use only new green O-ring seals. The use of any O-ring seals other than specified may result in intermittent leakage during vehicle operation. 4. Connect the spring lock coupling fittings with a twisting motion until the A/C tube lock coupling spring snaps over the flared end of the female fitting. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure > Page 8151 5. Install the A/C tube lock coupling clip. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure > Page 8152 Coupler HVAC: Service and Repair Peanut Fitting Connect and Disconnect Procedure DISCONNECT 1. Remove the nut from the peanut fitting. CAUTION: Support the female fitting with a wrench to prevent the tubes from twisting. 2. Pull the peanut fitting apart. 3. Remove the O-ring seal with a non-metallic tool. CAUTION: Do not use metal tools to remove the O-ring seal. They can cause axial scratches across the O-ring seal groove resulting in refrigerant leaks. CONNECT 1. Clean all dirt or foreign material from the fittings. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure > Page 8153 2. Install the O-ring seal. - Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. CAUTION: Use only new green O-ring seals. The use of any O-ring seals other than specified may result in intermittent leakage during vehicle operation. 3. Lubricate the inside of the fittings with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSR-M1C231-B. 4. Assemble the male and female fittings together. NOTE: When correctly assembled the male and female fittings should be flush. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair Evaporator Case: Service and Repair REMOVAL NOTE: The evaporator core is not separately serviceable, it is serviced only with the evaporator core housing assembly. Replacement of the suction accumulator is not required when repairing the refrigerant system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. If an evaporator core leak is suspected, the evaporator core must be leak tested before it is removed from the vehicle. 1. Remove the suction accumulator, please refer to Heating and Air Conditioning/ See: Accumulator HVAC 2. Disconnect the blower motor and the blower motor resistor electrical connectors. 3. Detach the windshield wiper fluid hose. Using suitable hose pinching pliers, disconnect the heater hoses. 4. Detach the heater control valve vacuum hose. 5. Disconnect the heater control valve vacuum hose and the vacuum supply hose. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Page 8157 6. Disconnect the condenser to evaporator tube spring lock coupling. 7. Disconnect the vacuum harness connector. Remove the nut. 8. Remove two nuts, one bolt, and the A/C evaporator housing. - Remove the nut located at the bottom of the A/C evaporator housing first. - To remove the A/C evaporator housing, rotate the A/C evaporator housing counterclockwise. Then tip the evaporator core end towards the front of the vehicle. INSTALLATION 1. To install, reverse the removal procedure. - Lubricate the refrigerant system with the correct amount of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent. See: Refrigerant Oil Addition. - Install new O-ring seals lubricated in amount of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent. - Lubricate the coolant hoses with MERPOL(R) or plain water only, if needed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Page 8158 Evaporator Case: Tools and Equipment Heater Hose Disconnect Tool Spring Lock Coupling Disconnect Tool (5/8 Inch) Disconnect Tool, Spring Lock Coupling Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Page 8159 Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications Evaporator Core: Specifications Accumulator To Evaporator Core Fitting 35-42 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 8163 Evaporator Core: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 8164 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 8165 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 8166 Evaporator Core: Description and Operation NOTE: Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. The A/C evaporator core is the plate/fin type with a unique refrigerant flow path. - A mixture of refrigerant and oil enters the bottom of the A/C evaporator core through the A/C evaporator core inlet tube and is routed so it flows through the partitioned first three plate/fin sections. - The next four plate/fin sections are partitioned to force the refrigerant to flow toward the other end of the A/C evaporator core. - Refrigerant then continues over to the remaining five plate/fin sections and then moves out of the A/C evaporator core through the A/C evaporator core outlet tube. - This S-pass flow pattern accelerates the flow of refrigerant and oil through the A/C evaporator core. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 8167 Evaporator Core: Testing and Inspection On-Vehicle Leak Test 1. Perform the Refrigerant Discharging and Recovery Procedure. See: Service and Repair/Refrigerant Discharging and Recovery procedure 2. Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the core tubes. 3. Clean the spring lock couplings. For additional information, refer to Spring Lock Coupling. See: Coupler HVAC/Service and Repair/Spring Lock Coupling Connect and Disconnect Procedure 4. Connect the appropriate test fittings from the R-12/R-134a Air Conditioning Test Fitting Set to the evaporator or condenser tube connections. 5. Connect the red and blue hoses from the R-134a Manifold (gauge Set to the test fittings on the A/C evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum pump. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to the test fittings. if available, use hoses without shut-off valves. If hoses with shut-off valves are used, make 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 shut-off valve does not open. 6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low pressure gauge indicates 101 kPa (30 in-Hg). The 45 minute evacuation is necessary to remove any refrigerant from oil left in the A/C evaporator core or A/C condenser core. If the refrigerant is not completely removed from the oil, outgassing will degrade the vacuum and appear as a refrigerant leak. 7. If the low pressure gauge reading will not drop to 101 kPa (30 in-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 installing a new A/C evaporator core or A/C condenser core. 8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump. Observe the low pressure gauge; it should remain at the 101 kPa (30 in-Hg) mark. If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101 kPa (30 in-Hg) 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 gauge valves open for an additional 30 minutes to remove any remaining refrigerant from the oil in the A/C evaporator core or A/C condenser core. Then recheck for loss of vacuum. - If a very small leak is suspected, allow the system to set overnight with vacuum applied and check for vacuum loss. 9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure, install a new A/C evaporator core or A/C condenser core. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 8168 Evaporator Core: Service and Repair REMOVAL NOTE: Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. If an A/C evaporator core leak is suspected, the A/C evaporator core must be leak tested before it is removed from the vehicle. 1. Disconnect the battery ground cable. 2. Perform the Refrigerant Discharging and Recovery Procedure, please refer to Heating and Air Conditioning/Service and Repair/ See: Service and Repair 3. Disconnect the A/C cycling switch. 4. Disconnect the electrical connectors. 1 Disconnect the A/C blower motor electrical connector. 2 Disconnect the A/C blower motor resistor electrical connector. 5. Disconnect the heater core. 1 Disconnect the heater water hoses. 2 Disconnect the heater water control valve vacuum hose. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 8169 6. Position the speed control servo aside. 1 Remove the (A) bolt and disconnect the (B) servo electrical connector. 2 Position the speed control servo aside. 7. Remove the nuts and the screws from the windshield washer reservoir/coolant recovery reservoir. Set the reservoir aside. 8. Disconnect the A/C manifold and tube from the suction accumulator/drier. 9. Disconnect the condenser to evaporator tube. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 8170 10. Disconnect the (B) A/C system vacuum harness and the (A) A/C evaporator housing mounting nut inside the vehicle. 11. Remove the A/C evaporator housing, please refer to Heating and Air Conditioning/Evaporator Case/Service and Repair/ See: Evaporator Case/Service and Repair 1 Remove the three underhood and one underdash nuts. 2 Lift the A/C evaporator housing out of the vehicle. 12. Disconnect the suction accumulator/drier from the A/C evaporator core. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 8171 13. Remove the screws attaching the housing cover. 14. Remove the A/C evaporator core. 1 Separate the evaporator case halves. 2 Lift the A/C evaporator core out. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 8172 1. To install, reverse the removal procedure. - Service the new A/C evaporator core with the correct amount of PAG compressor oil, YN-12-C, F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 8173 Evaporator Core: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool Set Disconnect Tool, Spring Lock Coupling Heater Hose Disconnect Tool Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications > Page 8174 Special Tool(s) Set, A/C Fittings Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 8178 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 8179 Expansion Block/Orifice Tube: Description and Operation A/C Evaporator Core Orifice NOTE: A new A/C evaporator core orifice should be installed whenever a new A/C compressor is installed. The A/C evaporator core orifice has the following characteristics: - It is color-coded red. - It has an orifice diameter of 1.6 mm (0.062 inch). - It is located in the A/C evaporator core inlet tube. - It has filter screens located on the inlet and outlet ends of the tube body. - The inlet filter screen acts as a strainer for the liquid refrigerant flowing through the A/C evaporator core orifice. - O-rings on the A/C evaporator core orifice prevent the high-pressure liquid refrigerant from bypassing the A/C evaporator core orifice. - Adjustment or service cannot be made to the A/C evaporator core orifice assembly. A new evaporator core orifice assembly must be installed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 8180 Expansion Block/Orifice Tube: Service and Repair SPECIAL SERVICE TOOL(S) REMOVAL 1. Remove the condenser to evaporator tube. 2. Engage the Fixed Orifice Tube Tool to the A/C evaporator core orifice. 3. Hold the tool T-handle stationary and rotate the tool body to remove the A/C evaporator core orifice. 4. To remove a broken A/C evaporator core orifice, screw the end of the Throttle Remover into the broken A/C evaporator core orifice. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 8181 5. Hold the tool T-handle stationary and rotate the tool body to remove the broken A/C evaporator core orifice. INSTALLATION 1. Lubricate and install the O-ring seals on the A/C evaporator core orifice. - Use PAG compressor oil, YN-12-C, F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. 2. Place the A/C evaporator core orifice into the Fixed Orifice Tube Tool. 3. Insert the A/C evaporator core orifice into the condenser to evaporator tube until seated. 4. Remove the Fixed Orifice Tube Tool. 5. Install the condenser to evaporator tube. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 8182 Expansion Block/Orifice Tube: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Special Tool(s) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Locations Expansion Valve: Locations For further information regarding this component please refer to: Heating and Air Conditioning; Expansion Block/Orifice Tube. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8194 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8195 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8201 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8202 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 8203 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 8204 Heater Core: Service Precautions WARNING: - CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 8205 Heater Core: Description and Operation The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer it to air passing through the heater core. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 8206 Heater Core: Testing and Inspection WARNING: CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. 1. Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good and did not require installation of a new heater core. If a heater core leak is suspected, the heater core must be tested by following the plugged heater core component test before the heater core pressure test. Carry out a system inspection by checking the heater system thoroughly. 2. Check the integrity of the heater water hose clamps. NOTE: Spring type clamps are installed as original equipment. Installation and overtightening of non-specification clamps can cause leakage at the heater water hose connection and damage the heater core. Heater Core-Plugged WARNING: THE HEATER CORE IN LET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. 1. Check to see that the engine coolant is at the correct level. 2. Start the engine and turn on the heater. 3. When the engine coolant reaches operating temperature, feel the heater core outlet hose to see if it is hot. If it is not hot. the heater core may have an air pocket - the heater core may be plugged - the thermostat is not working correctly. Heater Core-Pressure Test Use Radiator/Heater Core Pressure Tester to carry out the pressure test. 1. Drain the coolant from the cooling system. For additional information, refer to Cooling system. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water hose, approximately 101 mm (4 inches) long on each heater core tube. 4. Fill the heater core and heater water hoses with water and install Plug BT-7422-B and adapter BT-7422-A from the radiator/heater core pressure tester in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose clamps. 5. Attach the pump and gauge assembly from the Radiator/Heater Core Pressure Tester to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 241 kPa (35 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of three minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and carry out the bench test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 8207 Heater Core-Bench Test 1. Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. 3. Connect the 101 mm (4 inch) test heater water hoses with plug and adapter to the core tubes. Then connect the radiator/heater core pressure tester to the adapter. 4. Apply 241 kPa (35 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, install a new heater core. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 8208 Heater Core: Service and Repair Heater Core Removal and Installation Procedures Removal Note: If a heater core leak is suspected, the heater core must be leak tested before it is removed from the vehicle. 1. Drain the radiator. 2. Remove the heater water hose. 1. Squeeze the clamps and pull the hoses off. 2. Disconnect the vacuum hose from the water control valve. 3. Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 4. Remove the A/C evaporator core housing. 5. Remove the powertrain control module (PCM). 6. Remove the PCM heat sink. 1. Remove the ground strap screw. 2. Remove the heat sink. 7. Remove the heater air plenum nuts from the engine side of the dash panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 8209 8. Remove the heater core. 1. Remove the heater core cover to air plenum screws. 2. Lift off the cover. 9. Remove the heater core. Installation Note: Be sure to install a new oval foam seal around the heater core inlet and outlet tubes. 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Specifications Heater Core Case: Specifications Plenum Chamber Nuts 3.4-4.8 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Specifications > Page 8213 Heater Core Case: Service and Repair REMOVAL 1. Remove the dash board. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 2. Drain the radiator. 3. Disconnect the heater hoses from the heater core. 4. Remove the evaporator core housing, please refer to Heating and Air Conditioning/Evaporator Case/Service and Repair/ See: Evaporator Case/Service and Repair 5. Remove the nuts and remove the plenum chamber. INSTALLATION 1. Follow the removal procedure in reverse order. - Lubricate the hoses and fittings with Rubber Suspension Insulator Lube E25Y-1 9553-A or equivalent meeting Ford specification ESF-M99B112-A. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8222 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8223 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8229 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8230 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Page 8231 Heater Hose: Specifications Heater hose bracket bolts 27 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Page 8232 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications High Pressure Safety Valve HVAC: Specifications A/C Comprssor Pressure Relief valve 3103 kPa Opening Pressure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications > Page 8236 High Pressure Safety Valve HVAC: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications > Page 8237 Refrigeration System Components - 4.0L (5.0L Similar) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications > Page 8238 High Pressure Safety Valve HVAC: Description and Operation An A/C compressor pressure relief valve is incorporated in the compressor A/C manifold and tube to: - relieve unusually high refrigerant system discharge pressure buildups, (3,103 kPa [450 psi] and above). - prevent damage to the A/C compressor and other system components. - avoid total refrigerant loss by closing after the excessive pressure has been relieved. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications Hose/Line HVAC: Specifications Peanut Fitting Nut 7-9 Nm A/C Line To Condenser Nut 6.8-9.2 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications > Page 8242 Hose/Line HVAC: Description and Operation NOTE: Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. The condenser to evaporator tube contains high pressure liquid refrigerant upstream of the A/C evaporator core orifice. The A/C manifold and tube is attached to the A/C compressor with O-ring seals and has the following features: - The upstream side contains low pressure refrigerant gas. - The downstream side contains high pressure refrigerant gas and a fitting used to mount a serviceable high-pressure A/C charge port valve. - The downstream side also contains a fitting used to mount the A/C pressure cut-off switch. A long-travel Schrader-type valve stem core is installed in the fitting so that the A/C pressure cut-off switch can be removed without discharging the A/C system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications > Page 8243 Hose/Line HVAC: Service and Repair REMOVAL 1. Perform the Refrigerant Discharging and Recovery Procedure. 2. Disconnect the condenser to evaporator tube from the A/C condenser core. 3. Disconnect the condenser to evaporator tube spring lock coupling from the A/C evaporator core and remove the condenser to evaporator tube. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications > Page 8244 Spring Lock Coupling Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Locations Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation Receiver Dryer: Description and Operation For further information regarding this component and the system that it is part of, please refer to: Accumulator HVAC. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation > Page 8251 Receiver Dryer: Service and Repair For further information regarding this component and the system that it is part of, please refer to: Accumulator HVAC. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications System Capacity 30 oz (US) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 8256 Refrigerant: Fluid Type Specifications Refrigerant Type Ford YN-19 (R-134a) Specification WSH-M17B19-A Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 8257 Refrigerant: Service Precautions The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun. Ozone Depletion Scientific research performed over the past 15 years links the release of chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone depletion. When CFCs are released into the atmosphere, they eventually reach the ozone layer located in the stratosphere where they react with and destroy ozone molecules. Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown to lead to higher incidents of cancer as well as global warming. When viewed from a global perspective, ozone depletion holds an enormous potential for damage. Upper Level Vs. Ground Level Ozone Confusion often arises when we hear about the necessity of the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial but the same compound, when located at ground level, is harmful to humans, animals, crops and vegetation. Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with nitrogen oxides (NOx) in the presence of sunlight and heat. Montreal Protocol In response to the growing body of evidence demonstrating the detrimental effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become signatories to this agreement leading to an end of production of R12 in December, 1995, in all developed countries. As established by the Montreal Protocol, R12 production in developed countries has ceased. Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to control both the production and use of (CFC)s for refrigerant applications including mobile vehicle air conditioning systems. Additional Information Sources For more complete and detailed explanations of the above policies, please refer to: http://www.epa.gov/ozone/ Technician Certification Organizations providing technician refrigerant recovery and recycling certification include: National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2 Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/ International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX 76147-2000 Phone: (817) 732-4600 Fax: (817) 732-9610 http://www.imaca.org/ Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041 Phone: 215-679-2220 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 8258 Fax: 215-541-4635 http://www.macsw.org/ Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 8259 Refrigerant: Service and Repair SPECIAL SERVICE TOOL(S) 1. Prior to recovering the refrigerant system, you must verify the purity of the refrigerant. For additional information, refer to Refrigerant Identification Testing. See: Testing and Inspection/Component Tests and General Diagnostics/Identifying Refrigerants 2. Connect the R-134a A/C refrigerant center to the low and high-pressure service gauge port valves. NOTE: Some R-134a service centers require the use of an A/C manifold gauge set. For additional information, refer to Manifold Gauge Set Connection. See: Service and Repair/Manifold Gauge Set Connection 3. Perform the Refrigerant Discharging and Recovery Procedure. 4. Once the refrigerant center has recovered the vehicle A/C system refrigerant, close the refrigerant center inlet valve (if so equipped). Then switch off the power supply. 5. Allow the vehicle A/C system to remain closed for about two minutes. Observe the system vacuum level as shown on the gauge. If the pressure does not rise, disconnect the recovery station hose(s). 6. If the system pressure rises, repeat steps 2 through 5 until the vacuum level remains stable for two minutes. 7. Carry out the required repairs, then Perform the Evacuation and Charging Procedure. For additional information, refer to Evacuation and Charging. See: Service and Repair/Evacuation and Charging Procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications System Capacity 9 oz (US) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 8264 Refrigerant Oil: Fluid Type Specifications Lubricant PAG Compressor Oil Type YN-12c Part Number F7AZ-19589-DA Specification WSH-M1C231-B Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 8265 Refrigerant Oil: Service and Repair CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant, and small amount is retained in each component. If certain components of the system are removed, some of the refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. 1. Rotate the A/C compressor shaft six to eight revolutions while collecting oil in a clean measuring device. - If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 ounces), pour the same amount plus 30 ml (1 ounce) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 ounces), pour the same amount drained of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 ounces), pour 85 ml (3 ounces) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. NOTE: Service A/C compressors are shipped without compressor oil. 2. For the suction accumulator/drier, drill two 1/2 inch holes in the suction accumulator/drier cylinder and drain the oil into a calibrated container. - Add a quantity of new oil to match that drained from the old suction accumulator/drier plus 60 ml (2 ounces) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. 3. For the A/C evaporator core, add 89 ml (3 ounces) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 8266 4. For the A/C condenser core , add 30 ml (1 ounce) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B to the A/C condenser core or the suction accumulator/drier inlet tube. 5. Add 60 ml (2 ounces) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube when carrying out each of the following repairs: installation of a new A/C evaporator core orifice. - installation of a new A/C compressor pressure relief valve. - installation of a new refrigerant line. - repair of an O-ring seal leak. - repair of a charge port leak. 6. Installation of new components that do not require discharge of refrigerant and resulting oil loss, such as the A/C cycling switch and the A/C pressure transducer, do not require additional oil. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications Refrigerant Pressure Sensor / Switch: Specifications A/C Cycling Switch 324 kPa Close Minimum A/C Cycling Switch 152 kPa Open Minimum Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 8270 Refrigerant Pressure Sensor / Switch: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 8271 Manual A/C Electrical Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 8272 Electronic Automatic Temperature Control Electrical Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 8273 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch Refrigerant Pressure Sensor / Switch: Description and Operation A/C Cycling Switch A/C Cycling Switch The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction accumulator/drier. - A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. - This allows the suction pressure inside the suction accumulator/drier to control the operation of the A/C cycling switch. - The electrical switch contacts open when the suction pressure drops to 152-193 kPa (22-28 psi). - The contacts close when the suction pressure rises to 276-324 kPa (40-47 psi). - When the A/C cycling switch contacts close, the signal to energize the A/C clutch is sent to the wide open throttle A/C cutoff relay. - When the A/C cycling switch contacts open, the A/C clutch field coil is de-energized and compressor operation stops. - The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. - This prevents icing of the A/C evaporator core and blockage of airflow. - It is not necessary to discharge the refrigerant system to remove the A/C cycling switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 8276 Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning Cycling Switch PCM Inputs AIR CONDITIONING CYCLING SWITCH The Air Conditioning (A/C) cycling switch may be wired to either the A/C Cycling Switch (ACCS) or ACPSW Powertrain Control Module (PCM) input. When the A/C cycling switch opens, the PCM will turn off the Air Conditioning (A/C) clutch For information on the specific function of the A/C cycling switch, refer to Heating and Air Conditioning. The A/C Cycling Switch (ACCS) circuit to the PCM provides a voltage signal which indicates when the A/C is requested. When the A/C demand switch is turned on, and both the A/C cycling switch and the high pressure contacts of the A/C high pressure switch (if equipped and in circuit) are closed, voltage is supplied to the ACCS circuit at the PCM. Refer to Vehicle/Diagrams for vehicle specific wiring. If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate. For additional information, refer to PCM outputs, wide open throttle air conditioning cutoff. See: Powertrain Management/Description and Operation/PCM Outputs NOTE: Some applications do not have a dedicated (separate) input to the PCM indicating that A/C is requested. This information is received by the PCM through the BUS + and BUS - Standard Corporate Protocol (SCP) communication. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 8277 Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning High Pressure Switch Typical Air Conditioning Pressure Sensor The A/C pressure cut-off switch is used to interrupt A/C compressor operation in the event of high system discharge pressures. - The A/C pressure cut-off switch is mounted on a Schrader valve-type fitting on the high pressure side of the A/C manifold and tube. - A valve depressor, located inside the threaded end of the A/C pressure cut-off switch, presses on the Schrader valve stem. - This allows the A/C pressure cut-off switch to monitor the compressor discharge pressure. - When the compressor discharge pressure rises to approximately 2,896 kPa (420 psi), the switch contacts open, disengaging the A/C compressor. - When the pressure drops to approximately 1,724 kPa (250 psi), the contacts close to allow operation of the A/C compressor. - It is not necessary to discharge the refrigerant system to remove the A/C pressure cut-off switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 8283 Electronic Automatic Temperature Control Electrical Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 8284 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 8285 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 8286 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 8287 Blower Motor Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Compressor Clutch Relay Compressor Clutch Relay: Locations Compressor Clutch Relay Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Compressor Clutch Relay > Page 8292 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Compressor Clutch Relay > Page 8293 Compressor Clutch Relay: Locations Compressor Cut-Off Relay Manual A/C Electrical Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Compressor Clutch Relay > Page 8294 Electronic Automatic Temperature Control Electrical Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 8295 Compressor Clutch Relay: Description and Operation WIDE OPEN THROTTLE A/C CUT-OFF The Wide Open Throttle A/C Cut-Off Relay (may be referred to as the A/C clutch relay) is normally open. There is no direct electrical connection between the A/C switch or EATC Module and the A/C clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACP (SW), A/C Cycling Switch (ACCS)). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine rpm, throttle position), the PCM will ground the Wide Open Throttle A/C (WAC) output, closing the relay contacts and sending voltage to the A/C clutch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 8296 Compressor Clutch Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From Floor Ducts Control Module HVAC: Customer Interest A/C - Cold Air Blows From Floor Ducts Article No. 02-8-5 04/29/02 CLIMATE CONTROL - ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC) BLOWS COLD AIR FROM FLOOR DUCTS - VEHICLES PRODUCED BEFORE 9/30/2000 ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles produced before 9/30/2000 equipped with Electronic Automatic Temperature Control (EATC) may blow cold air from the floor ducts after the climate control system reaches a steady state in AUTO mode after switching from the FLOOR/DEFROST mode position to the FLOOR mode position, usually after driving for 15-30 minutes. This may be caused by the software version of the EATC Module. ACTION Update the software version or replace the EATC Module. Refer to the following Service Procedure for details. SERVICE PROCEDURE On vehicles equipped with the following EATC modules, F87H-18C612-BD, F87H-18C612-BE, XL2H-18C612-AA, or XL2H-18C612-AB, use NGS with Service Card Version 9.0 or later to update the EATC module software. On all other modules, replace the EATC module with service part YL2Z-19980-AA. Refer to section 412-04 of the appropriate model year Workshop Manual for removal and installation procedures. Use NGS with diagnostic card installed to verify the EATC module ID number (Engineering Part Number). NGS Procedure for Identifying EATC Module ID Number 1. Select "Diagnostics". 2. Select "EATC". 3. Select "Module I.D". NGS will display the EATC module I.D. number (Engineering Part Number). Vehicles that have been previously updated with this software will display "GO7H-BA". NGS Procedure for Updating Software 1. Select "Service Bay Functions". 2. Select "EATC" from module list. 3. Select "Module Configuration". 4. Select "99-01 Explorer" or "99-01 Mountaineer". Upon completion of the software upgrade, NGS will change the EATC module I.D to G07H-BA and display "Module Data Download Successfull". If the EATC module has been updated previously, or the module is not one of the modules listed as being capable of being updated, NGS will display "Can not update with the NGS". If the module is not capable of being updated, replace the module with part number YL2Z-19980-AA as listed above. Parts Block Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From Floor Ducts > Page 8305 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208300, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From Floor Ducts Control Module HVAC: All Technical Service Bulletins A/C - Cold Air Blows From Floor Ducts Article No. 02-8-5 04/29/02 CLIMATE CONTROL - ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC) BLOWS COLD AIR FROM FLOOR DUCTS - VEHICLES PRODUCED BEFORE 9/30/2000 ONLY FORD: 1998-2001 EXPLORER MERCURY: 1998-2001 MOUNTAINEER ISSUE Some vehicles produced before 9/30/2000 equipped with Electronic Automatic Temperature Control (EATC) may blow cold air from the floor ducts after the climate control system reaches a steady state in AUTO mode after switching from the FLOOR/DEFROST mode position to the FLOOR mode position, usually after driving for 15-30 minutes. This may be caused by the software version of the EATC Module. ACTION Update the software version or replace the EATC Module. Refer to the following Service Procedure for details. SERVICE PROCEDURE On vehicles equipped with the following EATC modules, F87H-18C612-BD, F87H-18C612-BE, XL2H-18C612-AA, or XL2H-18C612-AB, use NGS with Service Card Version 9.0 or later to update the EATC module software. On all other modules, replace the EATC module with service part YL2Z-19980-AA. Refer to section 412-04 of the appropriate model year Workshop Manual for removal and installation procedures. Use NGS with diagnostic card installed to verify the EATC module ID number (Engineering Part Number). NGS Procedure for Identifying EATC Module ID Number 1. Select "Diagnostics". 2. Select "EATC". 3. Select "Module I.D". NGS will display the EATC module I.D. number (Engineering Part Number). Vehicles that have been previously updated with this software will display "GO7H-BA". NGS Procedure for Updating Software 1. Select "Service Bay Functions". 2. Select "EATC" from module list. 3. Select "Module Configuration". 4. Select "99-01 Explorer" or "99-01 Mountaineer". Upon completion of the software upgrade, NGS will change the EATC module I.D to G07H-BA and display "Module Data Download Successfull". If the EATC module has been updated previously, or the module is not one of the modules listed as being capable of being updated, NGS will display "Can not update with the NGS". If the module is not capable of being updated, replace the module with part number YL2Z-19980-AA as listed above. Parts Block Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From Floor Ducts > Page 8311 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208300, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control - Blower Control Service Tips Control Module HVAC: All Technical Service Bulletins Climate Control - Blower Control Service Tips Article No. 00-21-3 10/16/00 CLIMATE CONTROL - EATC - BLOWER MOTOR CONTROL SERVICE TIPS FORD: 1990-1993 THUNDERBIRD 1990-2001 CROWN VICTORIA 1995-2001 EXPLORER LINCOLN: 1990-2001 TOWN CAR 2000-2001 LS MERCURY: 1990-1993 COUGAR 1990-2001 GRAND MARQUIS 1997-2001 MOUNTAINEER ISSUE The following service procedure has been developed to aid technicians in diagnosing EATC/DATC system blower motor control concerns. ACTION Refer to the following Service Procedure as an aid in helping diagnose blower motor control concerns. SERVICE PROCEDURE 1. Check blower motor operation in all speeds. ^ If the blower motor does not operate in any speed, refer to Step 2. ^ If the blower motor continuously operates in HIGH, refer to the appropriate pinpoint test in the Service/Workshop Manual. ^ If the blower motor does not operate in HIGH speed, refer to Step 3. ^ If the blower motor does not operate at speeds other than HIGH, refer to Step 4. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control - Blower Control Service Tips > Page 8316 NOTE: REFER TO FIGURE 1 FOR CONNECTOR VIEW. 2. Refer to the appropriate pinpoint test in the Service/Workshop Manual, except for checking the EATC/DATC module. When checking the EATC/DATC module, set the blower motor speed to HIGH blower and measure the voltage between the blower motor high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is 5 ohms or less, repair the circuit. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). Retest the system for normal operation. 3. Set the blower speed control to HIGH and measure the voltage between the blower motor control high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. 4. Set the blower speed control to any speed other than HIGH and measure the voltage between the blower motor control blower control circuit (Pin 2 at the controller) and ground at the EATC/DATC module. a. If the voltage is below 1 volt, measure the resistance between the blower motor speed controller connector Pin 1 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. b. If the voltage is between 1 and 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 2 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. c. If the voltage is greater than 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 1 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less; install a new blower motor speed controller (19E624). If. the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control - Blower Control Service Tips > Page 8317 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208300, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control - Blower Control Service Tips Control Module HVAC: All Technical Service Bulletins Climate Control - Blower Control Service Tips Article No. 00-21-3 10/16/00 CLIMATE CONTROL - EATC - BLOWER MOTOR CONTROL SERVICE TIPS FORD: 1990-1993 THUNDERBIRD 1990-2001 CROWN VICTORIA 1995-2001 EXPLORER LINCOLN: 1990-2001 TOWN CAR 2000-2001 LS MERCURY: 1990-1993 COUGAR 1990-2001 GRAND MARQUIS 1997-2001 MOUNTAINEER ISSUE The following service procedure has been developed to aid technicians in diagnosing EATC/DATC system blower motor control concerns. ACTION Refer to the following Service Procedure as an aid in helping diagnose blower motor control concerns. SERVICE PROCEDURE 1. Check blower motor operation in all speeds. ^ If the blower motor does not operate in any speed, refer to Step 2. ^ If the blower motor continuously operates in HIGH, refer to the appropriate pinpoint test in the Service/Workshop Manual. ^ If the blower motor does not operate in HIGH speed, refer to Step 3. ^ If the blower motor does not operate at speeds other than HIGH, refer to Step 4. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control - Blower Control Service Tips > Page 8323 NOTE: REFER TO FIGURE 1 FOR CONNECTOR VIEW. 2. Refer to the appropriate pinpoint test in the Service/Workshop Manual, except for checking the EATC/DATC module. When checking the EATC/DATC module, set the blower motor speed to HIGH blower and measure the voltage between the blower motor high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is 5 ohms or less, repair the circuit. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). Retest the system for normal operation. 3. Set the blower speed control to HIGH and measure the voltage between the blower motor control high blower relay circuit (Pin 3 at the controller) and ground at the EATC/DATC module connector. a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper operation. b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the blower motor speed controller connector Pin 3 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. 4. Set the blower speed control to any speed other than HIGH and measure the voltage between the blower motor control blower control circuit (Pin 2 at the controller) and ground at the EATC/DATC module. a. If the voltage is below 1 volt, measure the resistance between the blower motor speed controller connector Pin 1 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal operation. b. If the voltage is between 1 and 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 2 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller (19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. c. If the voltage is greater than 3 volts, measure the resistance of the circuit between the blower motor speed controller connector Pin 1 and the corresponding pin at the EATC/DATC module connector. If the resistance is 5 ohms or less; install a new blower motor speed controller (19E624). If. the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control - Blower Control Service Tips > Page 8324 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208300, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 8327 Control Module HVAC: Locations Blower Motor Speed Control Electronic Automatic Temperature Control Electrical Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 8328 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Electronic Climate Control Module Control Module HVAC: Diagrams Electronic Climate Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Electronic Climate Control Module > Page 8331 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Page 8332 Control Module HVAC: Description and Operation The blower speed control is located on the evaporator housing in the engine compartment. - The function of the blower motor speed control is to convert low power signals from the electronic automatic temperature control module to a high current, variable ground feed for the blower motor. - The blower motor speed is infinitely variable and is controlled by the electronic automatic temperature control module software. - A delay function provides a gradual increase or decrease in blower motor speed under all conditions. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Service and Repair Air Conditioning Switch: Service and Repair REMOVAL 1. Remove the climate control assembly. 2. Remove the heater blower motor switch. 1 Remove the screw. 2 Rotate and remove the heater blower motor switch. NOTE: The knob will come off when the switch is removed. 3. Remove the temperature control switch and the A/C damper door switch. 1 Remove the screw. 2 Rotate and remove the temperature control switch. 3 Rotate and remove the A/C damper door switch. NOTE: The knobs will come off when the switch is removed. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 8340 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 8341 Ambient Temperature Sensor / Switch HVAC: Description and Operation The A/C ambient air temperature sensor and bracket: - is located in front of the A/C condenser core near the center of the vehicle. - contains a thermistor which measures the temperature of outside air as a resistance and sends that reading to the electronic automatic temperature control assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 8348 Cabin Temperature Sensor / Switch: Description and Operation The in-car temperature sensor operates in the following manner: - A thermistor in the in-car temperature sensor measures air temperature inside the passenger compartment. - An automatic temperature control sensor hose and elbow is connected between the plenum assembly and the in-car temperature sensor. - The automatic temperature control sensor hose and elbow takes air from the plenum assembly air stream to create a suction in the in-car temperature sensor. - The suction draws in-vehicle air into the in-car temperature sensor and across the thermistor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications Refrigerant Pressure Sensor / Switch: Specifications A/C Cycling Switch 324 kPa Close Minimum A/C Cycling Switch 152 kPa Open Minimum Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 8352 Refrigerant Pressure Sensor / Switch: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 8353 Manual A/C Electrical Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 8354 Electronic Automatic Temperature Control Electrical Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Page 8355 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch Refrigerant Pressure Sensor / Switch: Description and Operation A/C Cycling Switch A/C Cycling Switch The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction accumulator/drier. - A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. - This allows the suction pressure inside the suction accumulator/drier to control the operation of the A/C cycling switch. - The electrical switch contacts open when the suction pressure drops to 152-193 kPa (22-28 psi). - The contacts close when the suction pressure rises to 276-324 kPa (40-47 psi). - When the A/C cycling switch contacts close, the signal to energize the A/C clutch is sent to the wide open throttle A/C cutoff relay. - When the A/C cycling switch contacts open, the A/C clutch field coil is de-energized and compressor operation stops. - The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. - This prevents icing of the A/C evaporator core and blockage of airflow. - It is not necessary to discharge the refrigerant system to remove the A/C cycling switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 8358 Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning Cycling Switch PCM Inputs AIR CONDITIONING CYCLING SWITCH The Air Conditioning (A/C) cycling switch may be wired to either the A/C Cycling Switch (ACCS) or ACPSW Powertrain Control Module (PCM) input. When the A/C cycling switch opens, the PCM will turn off the Air Conditioning (A/C) clutch For information on the specific function of the A/C cycling switch, refer to Heating and Air Conditioning. The A/C Cycling Switch (ACCS) circuit to the PCM provides a voltage signal which indicates when the A/C is requested. When the A/C demand switch is turned on, and both the A/C cycling switch and the high pressure contacts of the A/C high pressure switch (if equipped and in circuit) are closed, voltage is supplied to the ACCS circuit at the PCM. Refer to Vehicle/Diagrams for vehicle specific wiring. If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate. For additional information, refer to PCM outputs, wide open throttle air conditioning cutoff. See: Powertrain Management/Description and Operation/PCM Outputs NOTE: Some applications do not have a dedicated (separate) input to the PCM indicating that A/C is requested. This information is received by the PCM through the BUS + and BUS - Standard Corporate Protocol (SCP) communication. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 8359 Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning High Pressure Switch Typical Air Conditioning Pressure Sensor The A/C pressure cut-off switch is used to interrupt A/C compressor operation in the event of high system discharge pressures. - The A/C pressure cut-off switch is mounted on a Schrader valve-type fitting on the high pressure side of the A/C manifold and tube. - A valve depressor, located inside the threaded end of the A/C pressure cut-off switch, presses on the Schrader valve stem. - This allows the A/C pressure cut-off switch to monitor the compressor discharge pressure. - When the compressor discharge pressure rises to approximately 2,896 kPa (420 psi), the switch contacts open, disengaging the A/C compressor. - When the pressure drops to approximately 1,724 kPa (250 psi), the contacts close to allow operation of the A/C compressor. - It is not necessary to discharge the refrigerant system to remove the A/C pressure cut-off switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations Solar Sensor: Locations Electronic Automatic Temperature Control Electrical Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 8363 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 8364 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 8365 Solar Sensor: Description and Operation The A/C sunload sensor: - is located on the top side of the instrument panel. - contains a photovoltaic diode that is sensitive to light. - has some unspecified resistance across the terminals depending upon the amount of light reaching the photovoltaic diode; therefore the only test that can be performed is for an internal short circuit. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations Service Port HVAC: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 8369 Refrigeration System Components - 4.0L (5.0L Similar) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 8370 Service Port HVAC: Description and Operation The high-pressure service gauge port valve is located on the front A/C manifold and tube. The low pressure service gauge port valve is located on the suction accumulator/drier. The fitting is an integral part of the refrigeration line or component. - Special couplings are required for both the high-side and low-side service gauge ports. - A new Schrader-type valve core can be installed if the seal leaks. - Always install the A/C charging valve cap on the service gauge port valve after repairing the refrigerant system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations Solar Sensor: Locations Electronic Automatic Temperature Control Electrical Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 8374 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 8375 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 8376 Solar Sensor: Description and Operation The A/C sunload sensor: - is located on the top side of the instrument panel. - contains a photovoltaic diode that is sensitive to light. - has some unspecified resistance across the terminals depending upon the amount of light reaching the photovoltaic diode; therefore the only test that can be performed is for an internal short circuit. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service Precautions > Customer Safety Information Vacuum Harness HVAC: Customer Safety Information WARNING: BEFORE USING, OR HANDLING COMMERCIALLY AVAILABLE PAINT THINNER CONTAINING METHYL ETHYL KETONE (MEK), READ AND FOLLOW THE WARNING INFORMATION ON THE PRODUCT LABEL. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service Precautions > Customer Safety Information > Page 8381 Vacuum Harness HVAC: Technician Safety Information WARNING: BEFORE USING, OR HANDLING COMMERCIALLY AVAILABLE PAINT THINNER CONTAINING METHYL ETHYL KETONE (MEK), READ AND FOLLOW THE WARNING INFORMATION ON THE PRODUCT LABEL. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service Precautions > Page 8382 Vacuum Harness HVAC: Service and Repair VACUUM HOSE REPAIR - MINI TUBE Vacuum Pump Kit SPECIAL SERVICE TOOL(S) 1. Measure the length of the damaged area of the mini-tube vacuum hose. 2. Cut a piece of standard 1/8 inch inner diameter vacuum hose approximately 25 mm (1 inch) longer than the damaged area of the mini-tube vacuum hose. 3. Cut off the mini-tube vacuum hose on each side of the damaged area. 4. Dip the mini-tube hose ends in commercially available paint thinner containing Methyl Ethyl Ketone (MEK). This solvent will seal the mini-tube in the vacuum hose. WARNING: READ THE WARNING INFORMATION ON THE PRODUCT LABEL TO PREVENT POSSIBLE INJURY. 5. Insert the ends of the mini-tube vacuum hose approximately 9 mm (3/8 inch) into the ends of the standard 1/8 inch service vacuum hose section. 6. Shake the service joint after assembly to make sure the solvent is dispersed and the vacuum line is not plugged. 7. Test the system for a vacuum leak in the repair area. - Use the Vacuum Tester or equivalent. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service Precautions > Page 8383 Vacuum Tester Kit Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment Repairs and Inspections Required After a Collision: Service and Repair Inspection and Repair After A Supplemental Restraint System (SRS) Deployment INSPECTION AND REPAIR AFTER A SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPLOYMENT WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. NOTE: After diagnosing or repairing a SRS the restraint system diagnostic tools must be removed before operating the vehicle over the road. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. When any deployable device (driver air bag, passenger air bag, seat side air bag, safety belt pretensioner, etc.) or combination of devices are deployed and/or the ECS module has the DTC B1231 (Crash Data Memory Full) in memory, the repair of the vehicle's supplemental restraint system (SRS) is to include the removal of all deployed devices and installation of new deployable devices, the removal and installation of new impact sensors, and the removal and installation of a new ECS module. 2. When any damage to the impact sensor mounting points or mounting hardware has occurred, repair or install new mounting points and mounting hardware as needed. 3. When the driver air bag module has deployed a new clockspring must be installed. 4. Inspect the entire vehicle for damage, including the following components: - steering column. - instrument panel knee bolsters and mounting points. - instrument panel braces and brackets. - instrument panel and mounting points. - seats and seat mounting points. - safety belts, safety belt buckles, and safety belt retractors. - Information. - supplemental restraint system (SRS) wiring, wiring harnesses, and connectors. 5. After carrying out the review and inspection of the entire vehicle for damage, repair or install new components as needed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment > Page 8389 Repairs and Inspections Required After a Collision: Service and Repair Safety Belt Procedure After A Collision SAFETY BELT PROCEDURE AFTER A COLLISION WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support assemblies (slide bar), shoulder belt height adjusters, child safety seat tether attachments (if equipped), and attaching hardware should be inspected after any collision. New belt assemblies should be installed unless a qualified technician finds the assemblies show no damage and operate correctly. Belt assemblies not in use during a collision should also be inspected and replaced if either damage or incorrect operation is noted. NOTE: Safety belt assemblies should be periodically inspected to make sure they have not become damaged and that they remain in correct 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. Perform the Functional Test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING:To reduce the risk of personal injury, do not use any memory saver devices. NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram See: . 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8395 7. Remove the two steering wheel back cover plugs. 8. Remove the two driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. 10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical connector at the clockspring. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8396 11. Open the glove compartment door to access the passenger air bag module mounting screws. 12. Remove the two screws. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove box opening, push out on the passenger air bag module and separate it from the instrument panel. 14. Disconnect the electrical connector and remove the passenger air bag module. 15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the passenger air bag module electrical connector. Vehicles equipped with seat side air bags Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8397 16. Disconnect the passenger seat side air bag module electrical connector located under the passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector located under the driver seat. 19. Connect the restraint system diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical connector. All vehicles 20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground cable. Reactivation Procedure All vehicles 1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles equipped with seat side air bags 3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side air bag module electrical connector located under the driver seat. 4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint system diagnostic tool from the body harness side of the passenger seat side air bag module electrical connector located under the passenger seat. 6. Connect the passenger seat side air bag module electrical connector All vehicles 7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air bag module electrical connector. 8. Install the passenger air bag module. 9. Connect the passenger air bag module electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8398 10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical connector at the clockspring. 11. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag module to the steering wheel. 12. Install the two driver air bag module retaining bolts. 13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON. 15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 17. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8399 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle battery connected? Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8400 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Prove out the system means to turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > Customer Interest: > 03-24-1 > Dec > 03 > Restraint System - Air Bag Lamp ON/DTC B1994/B1998 Air Bag Harness: Customer Interest Restraint System - Air Bag Lamp ON/DTC B1994/B1998 Article No. 03-24-1 12/08/03 ELECTRICAL - AIRBAG LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B1994 AND/OR B1998 FORD: 1999-2001 EXPLORER SPORT, EXPLORER MERCURY: 1999-2001 MOUNTAINEER This article supersedes TSB 01-1-10 to update the model years and vehicle line coverage. ISSUE Some 1999-2001 Explorer/Mountaineer 4DR and Explorer Sport 2DR vehicles may exhibit an airbag lamp illuminated intermittently with diagnostic trouble codes (DTC's) B1994 or B1998 stored in memory. This may be due to a high resistance or poor connections in the side air bag (SAB) wiring harness circuits or restraints control module. This condition may occur on vehicles equipped with, or without, side air bags. ACTION To service, install an overlay harness which incorporates soldered terminals and tin wiring. Refer to the service procedure for direction on which side air bag kit to order. Installation instructions and illustrations are included in the kit. SERVICE PROCEDURE FOR VEHICLES WITHOUT THE (SAB), FOURTH DIGIT OF VIN IS "Y" OR "Z" 1. Install a new Non-SAB wire harness kit 3L2Z-14B455-AB. Refer to the installation instruction sheet included in the kit. FOR VEHICLES EQUIPPED WITH (SAB), FOURTH DIGIT OF VIN IS "C" OR "D" 1. Install the appropriate harnesses as indicated below. Refer to the installation instruction sheet included in the kit. ^ 1999-2001 4DR Limited Explorer XL2Z-14B455-DB ^ 1999-2001 4DR Explorer (except Limited) and Mountaineer XL2Z-14B455-AC ^ 1999-2000 2DR Explorer XL2Z-14B455-BC ^ 2001 2DR Explorer 1L2Z-14B455-AC Reference section 501-20A of the appropriate model year Workshop Manual for additional information if needed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > Customer Interest: > 03-24-1 > Dec > 03 > Restraint System - Air Bag Lamp ON/DTC B1994/B1998 > Page 8410 Labor Operation Claiming Chart OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-01-10 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14B455 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-24-1 > Dec > 03 > Restraint System - Air Bag Lamp ON/DTC B1994/B1998 Air Bag Harness: All Technical Service Bulletins Restraint System - Air Bag Lamp ON/DTC B1994/B1998 Article No. 03-24-1 12/08/03 ELECTRICAL - AIRBAG LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B1994 AND/OR B1998 FORD: 1999-2001 EXPLORER SPORT, EXPLORER MERCURY: 1999-2001 MOUNTAINEER This article supersedes TSB 01-1-10 to update the model years and vehicle line coverage. ISSUE Some 1999-2001 Explorer/Mountaineer 4DR and Explorer Sport 2DR vehicles may exhibit an airbag lamp illuminated intermittently with diagnostic trouble codes (DTC's) B1994 or B1998 stored in memory. This may be due to a high resistance or poor connections in the side air bag (SAB) wiring harness circuits or restraints control module. This condition may occur on vehicles equipped with, or without, side air bags. ACTION To service, install an overlay harness which incorporates soldered terminals and tin wiring. Refer to the service procedure for direction on which side air bag kit to order. Installation instructions and illustrations are included in the kit. SERVICE PROCEDURE FOR VEHICLES WITHOUT THE (SAB), FOURTH DIGIT OF VIN IS "Y" OR "Z" 1. Install a new Non-SAB wire harness kit 3L2Z-14B455-AB. Refer to the installation instruction sheet included in the kit. FOR VEHICLES EQUIPPED WITH (SAB), FOURTH DIGIT OF VIN IS "C" OR "D" 1. Install the appropriate harnesses as indicated below. Refer to the installation instruction sheet included in the kit. ^ 1999-2001 4DR Limited Explorer XL2Z-14B455-DB ^ 1999-2001 4DR Explorer (except Limited) and Mountaineer XL2Z-14B455-AC ^ 1999-2000 2DR Explorer XL2Z-14B455-BC ^ 2001 2DR Explorer 1L2Z-14B455-AC Reference section 501-20A of the appropriate model year Workshop Manual for additional information if needed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-24-1 > Dec > 03 > Restraint System - Air Bag Lamp ON/DTC B1994/B1998 > Page 8416 Labor Operation Claiming Chart OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-01-10 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14B455 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8422 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8423 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8429 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Harness: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 8430 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications Air Bag Control Module: Specifications Restraint Control Module Bracket 12 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 8434 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 8435 Air Bag Control Module: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 8436 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 8437 Air Bag Control Module: Description and Operation The Restraints Control Module (RCM) carries out the following functions: ^ signals the inflators to deploy the air bags in the event of a deployable crash. ^ monitors the air bag Supplemental Restraint System (SRS) for faults. ^ illuminates the air bag indicator if a fault is detected. ^ flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected. ^ communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble Codes (DTCs). ^ signals the Generic Electronic Module (GEM) to activate a chime if the air bag indicator is not available and another SRS fault exists. NOTE: The safety sensor is internal to the RCM and is not serviced separately. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the RCM will illuminate the air bag indicator located in the instrument cluster. When the ignition is cycled (turned off and then on), the air bag indicator will prove out by lighting for six seconds and then off for two seconds. After the prove out, the air bag indicator will then flash the two-digit LFC. If an SRS fault exists, the air bag indicator will flash the LFC five times, then it will remain illuminated for the rest of the key cycle. The RCM will also communicate the current and historical DTCs through the DLC, to the scan tool. If the air bag indicator does not function, and the system detects a fault condition, the RCM will signal the GEM to activate an audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed. After that fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors determine that a deployment is required. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation Air Bag Control Module: Service and Repair Removal and Installation REMOVAL WARNING: ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION IN WHICH THE RIGHT COWL A-PILLAR AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the right hand cowl side trim panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 8440 3. Disconnect the Restraints Control Module (RCM). 1 Slide the two RCM electrical connector locking clips down to disengage them. 2 While squeezing the locking clip area to pivot the latch, disconnect the two RCM electrical connectors. 4. Remove the RCM with bracket. 1 Remove the three RCM bracket retaining bolts. 2 Remove the RCM with bracket. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 8441 1. Follow the removal procedure in reverse order. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: A repair is made by installing a new part only. If the part does not correct the condition, install the original part and perform the diagnostic procedure again. 2. Prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 8442 Air Bag Control Module: Service and Repair Weld Nut Repair "J" Nut WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both procedures before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J" nuts as outlined in this procedure. Weld nuts must be installed as outlined in Weld Nut Repair- Missing Weld Nut, Restraints Control Module (RCM), Front External Crash and Side Crash Sensor. ^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is in close proximity to the missing weld nut. 1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part numbers: N623342-S101, N800854-S100, N800925-S100). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190) or equivalent. 3. Install the "J" nut through the rectangular hole in the sheet metal. 4. Install the crash sensor. NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet metal. 5. Tighten the attaching screws to specification. Stripped Weld Nut WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455-S190). 2. Drill out the internal threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification. Missing Weld Nut WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 8443 LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both procedures before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J", nuts as outlined in Weld Nut Repair "J" Nut, Restraints Control Module (RCM), Front External Crash and Side Crash Sensor. Weld nuts must be installed as outlined in this procedure. ^ Radiator support repair shown, others are similar. 1. Obtain a 6 mm (0.24 in) weld nut (part number N806285-S190). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-5190). 3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back out an adjacent access hole. 4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5. Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the copper welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole, firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld nut in position. 8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the edge of the weld nut. 9. Metal finish as required. 10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws to specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Specifications Clockspring Assembly / Spiral Cable: Specifications Steering Column Fore And Aft Nuts 15 Nm Lower Steering Column Opening Finish Panel Reinforcement 12 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Specifications > Page 8447 Clockspring Assembly / Spiral Cable: Diagrams With Auxiliary Controls Without Auxiliary Controls Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Specifications > Page 8448 Clockspring Assembly / Spiral Cable: Description and Operation The air bag sliding contact: ^ is mounted on the steering column, behind the steering wheel. ^ continuously transfers electrical signals from the driver air bag module to the Restraints Control Module (RCM). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Specifications > Page 8449 Clockspring Assembly / Spiral Cable: Service and Repair REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED TRIM COVERS MUST BE REPLACED, NOT REPAINTED. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the driver air bag module. 3. Remove the steering wheel. NOTE: Make sure the wheels are in the straight-ahead position. 4. Apply two strips of masking tape across the air bag sliding contact to prevent accidental rotation when the air bag sliding contact is removed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Specifications > Page 8450 5. Remove the lower steering column opening finish panel. 1 Remove the retaining screws and position the hood release handle out of the way. 2 Remove the two retaining screws from the lower steering column opening finish panel. 3 Pull out to release the retaining clips and remove the lower steering column opening finish panel. 6. Remove the four retaining bolts and remove the lower steering column opening finish panel reinforcement. 7. Loosen, but do not remove, the four steering column to instrument panel retaining bolts enough to remove the upper steering column shroud (two shown). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Specifications > Page 8451 8. Remove the lower steering column shroud. 1 If equipped, remove the tilt wheel handle and shank. 2 Remove the three screws. 3 Remove the lower steering column shroud. 9. Remove the ignition switch lock cylinder. 1 Position the ignition switch lock cylinder to the RUN position. 2 Using the suitable tool, push upward on the cylinder release tab while pulling the ignition switch lock cylinder outward. 10. Remove the upper steering column shroud. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Specifications > Page 8452 11. Remove the Passive Anti-Theft System (PATS) transmitter. 1 Remove the PATS transmitter retaining screw. 2 Position the PATS transmitter out of the way. 12. Remove the key-in-ignition warning indicator switch. 13. Remove the two air bag sliding contact wire connectors from the wire connector bracket and disconnect them. 14. Remove the wire harness from the two holders (one shown). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Specifications > Page 8453 15. Release the lower air bag sliding contact retaining clip. 16. Remove the air bag sliding contact. 1 Release the remaining two air bag sliding contact retaining clips. 2 Remove the air bag sliding contact. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Specifications > Page 8454 1. Follow the removal procedure in reverse order. 2. Prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Side Crash Sensor 12 Nm Front Crash Sensor 10.2-13.8 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Driver Side Air Bag Crash Sensor Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Driver Side Air Bag Crash Sensor > Page 8460 Impact Sensor: Locations Front Crash Sensors Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Driver Side Air Bag Crash Sensor > Page 8461 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Driver Side Air Bag Crash Sensor > Page 8462 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Driver Side Air Bag Crash Sensor > Page 8463 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front External Crash Sensor Impact Sensor: Service and Repair Front External Crash Sensor REMOVAL WARNING: ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: A repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the radiator grill and radiator opening cover. 3. Remove the air bag sensor. 1 Disconnect the air bag sensor electrical connector. 2 Remove the three screws. 3 Remove the air bag sensor. INSTALLATION WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: A repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front External Crash Sensor > Page 8466 1. Follow the removal procedure in reverse order. 2. Prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front External Crash Sensor > Page 8467 Impact Sensor: Service and Repair Side Crash Sensor REMOVAL WARNING: ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. ^ Right side is shown, left side is similar. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the B-pillar lower trim panel with scuff plates. NOTE: ^ Four door is shown, two door is similar. ^ The front seat has been removed for clarity. 3. Remove the side crash sensor. 1 Disconnect the side crash sensor electrical connector. 2 Remove the two retaining bolts. 3 Remove the side crash sensor with bracket. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front External Crash Sensor > Page 8468 WARNING: ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Follow the removal procedure in reverse order. 2. Prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Specifications Side Air Bag: Specifications AdjusterLatch/Pivot Cover Screw 1.6-2.2 Nm Battery Ground Cable Bolt 7-10 Nm Center Occupant Safety Belt Bolt 30-40 Nm Driver Seat Module Screws 12 Nm Front/Rear Seat Backrest Latch Bolts 47-63 Nm Front Seat Back Pad Adjusting Pump Bolt 11-14 Nm Front Seat Cushion Side Cover Screws 1.6-2.2 Nm Front Seat Inboard Pivot Bolt 19-26 Nm Front Seat Track To Floor Bolts 21-28 Nm Inboard Safety Belt Bracket Bolt 38-44 Nm Latch Handle Screws 1.6-2.2 Nm Link Arm Nut 30-40 Nm Rear Outboard Bolt 30-40 Nm Rear Outboard Nut 30-40 Nm Rear Seat Back Inboard/Outboard Pivot Bolts 38-44 Nm Rear Seat Riser To Floor Nuts 30-40 Nm Rear Seat Riser Pivot Bolts 38-44 Nm Rear Seat Link Bolt 30-40 Nm Rear Seat To Floor Bolts 30-40 Nm Safety Belt Buckle Bracket To Floor Nuts 34-46 Nm Seat Cushion To Adjuster Latch Bolts, Rear Seat 38-44 Nm Seat Track To Seat Cushion Bolts 17-23 Nm Side Air Bag Nuts 8 Nm Slide Bar To Floor Bolt 40 Nm Slide Bar To Seat Track Bolt 7.5-10.5 Nm Slide Bar To Seat Track Nut 7.5-10.5 Nm 40% Seat Inboard Pivot Bolts 23-32 Nm 50% Seat Cushion To Seat Hinge Bolts 7-11 Nm 50/50 Seat Back Latch Bolt 30-46 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Specifications > Page 8472 60% Front Seat Armrest Bolt 30-35 Nm 60% Seat Cushion Outboard Side Bolster Screw 1.6-2.2 Nm 60% Seat Inboard Pivot Cover Bolt 1.6-2.2 Nm Side Air Bag Module 8 Nm Seat Back Pivot Bolt 29 Nm Seat Back Recliner Bolts 52 Nm Track To Cushion Frame 20 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Specifications > Page 8473 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Technician Safety Information Side Air Bag: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN ON THE COVER TEAR SEAM. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service Precautions > Technician Safety Information > Page 8476 Side Air Bag: Vehicle Damage Warnings WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN ON THE COVER TEAR SEAM. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module Side Air Bag: Service and Repair Side Air Bag Module REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN ON COVER TEAR SEAM. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ When replacing the side air bag after deployment, refer to information concerning the installation of a new side air bag. ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. ^ Front driver seat is shown, passenger seat is similar. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the seat from the vehicle. WARNING: FRONT SEAT BACK TRIM COVERS INSTALLED ON SEATS EQUIPPED WITH SIDE AIR BAGS CANNOT BE REPAIRED; THEY ARE TO BE REPLACED (CLEANING IS PERMISSIBLE). 3. Disconnect the seat motor electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8479 4. Remove the four bolts (two shown) and the seat track from the seat bottom. 5. Disconnect the power seat switch electrical connector. 6. Pull and remove the manual lumbar support adjustment handle and remove the lower seat trim panel retaining screw. NOTE: Release all tension from the manual lumbar support cable. 7. Press the tabs in on the two retaining clips (one shown) and separate the lower seat trim panel from the seat bottom frame. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8480 8. Remove the lower seat trim panel. 1 Disconnect the heated seat switch (if equipped). 2 Remove the lower seat trim panel. 9. Remove the push pin holder from the seat bottom frame for the lumbar support cable. 10. Separate the lumbar support cable assembly. 1 Separate the lumbar support case assembly by sliding apart. 2 Remove the cable end ball from the cable end retainer and separate. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8481 11. Remove the push pin retaining the heated seat back electrical connector to the seat bottom frame. 12. Disconnect the heated seat back electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8482 13. Remove the side air bag electrical connector and wire harness push pins from the seat bottom frame. 14. Remove the push pin from the side air bag electrical connector. 15. Remove the two retaining bolts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8483 16. Laying the seat on its other side, remove the retaining bolt for the seat pivot, being careful not to damage the seat pivot, cable or any of the wires. CAUTION: When positioning the seat or separating the seat bottom from the back, be careful not to damage the seat back pivot and any of the wires or cables from the seat back to the seat bottom. This can cause damage to one of the seat components. 17. Remove the seat back from the seat bottom. 1 Pull the heated seat wire harness through the seat bottom. 2 Pull the lumbar support cable through the seat bottom. 3 Pull the side air bag module wire harness through the seat bottom. 4 Remove the seat back from the seat bottom. 18. Separate the seat back trim cover lower J-clip. 19. Remove and discard the hog rings from the two swing rods (one shown). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8484 20. Slide the swing rods out of the seat back trim cover. 21. Roll the seat back trim cover, in an inside out fashion, to the side air bag deployment chute. CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip. The hook and loop strip can be torn from the seat cushion foam. 22. Unzip the side air bag deployment chute. 23. Roll the seat back cover and side air bag deployment chute to completely expose the side air bag module and mounting bracket. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8485 24. Remove the side air bag wire harness tie strap retainer. 25. Position the side air bag module aside, through the seat back cushion opening. ^ Remove the retaining nuts. NOTE: If installing a new side air bag module, use new retaining nuts. If the same side air bag module is to be reused, then reuse the side air bag module retaining nuts. 26. Remove the side air bag module. 1 Slide the side air bag module electrical connector locking clip to disengage it. 2 Release the connector tabs by pushing in on them, then disconnect the side air bag module electrical connector. 3 Remove the side air bag module. INSTALLATION WARNING: Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8486 ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Connect the side air bag module electrical connector. 1 Install the connector to the side air bag module. 2 Slide the side air bag module electrical connector locking clip to secure the connector to the side air bag module. 2. Make sure the electrical connector is securely fastened to the side air bag module. WARNING: ^ INSPECT THE MOUNTING SURFACES OF THE SIDE AIR BAG MODULE AND THE SEAT BACK FRAME MOUNTING BRACKET FOR ANY FOREIGN OBJECTS BEFORE INSTALLING THE SIDE AIR BAG MODULE. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ INSPECT THE SIDE AIR BAG DEPLOYMENT CHUTE AND THE SIDE AIR BAG CAVITY IN THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ IF THE AIR BAG COVER HAS SEPARATED OR THE AIR BAG MATERIAL HAS BEEN EXPOSED, INSTALL A NEW SIDE AIR BAG MODULE. DO NOT ATTEMPT TO REPAIR THE AIR BAG MODULE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE OR ZIPPER, THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE REPLACED AS A UNIT. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8487 3. Install the side air bag module onto the front seat back frame mounting bracket, making sure the side air bag wiring harness is located behind the seat backrest frame and side air bag module mounting bracket. 1 Position the side air bag module onto the front seat back mounting bracket. 2 Install the side air bag module retaining nut. 3 Install the side air bag module retaining nut. 4 Install the side air bag module retaining nut. CAUTION: ^ The retaining nuts of the side air bag module must be tightened in the sequence described. ^ Make sure the side air bag wiring harness is not pinched between the side air bag module and the mounting bracket. 4. Tie-strap the side air bag module wire harness to the seat back frame. 5. Unroll the seat back trim cover, to position the deployment chute around the side air bag module. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8488 6. Position the air bag deployment chute. 1 Insert the outboard side of the air bag deployment chute between the seat back pad and the side air bag module, pulling it around the outboard side of the seat back frame. 2 Insert the inboard side of the air bag deployment chute between the seat back pad and the side air bag module from the inboard side of the seat back. WARNING: ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE OR ZIPPER THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT. ^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED AND COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY. 7. Zip the air bag deployment chute completely closed, then position the zipper tail at the top and bottom of the deployment chute, into the seat back opening. ^ The side air bag deployment chute must encircle the side air bag module, going completely around the side air bag module and the side of the seat back frame. ^ Align the side air bag deployment chute to the side air bag module, making sure it covers the length of the side air bag module. NOTE: Be sure the side air bag deployment chute is properly positioned, before proceeding. 8. Unroll the seat back trim cover to the bottom row of hog rings. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8489 9. Install the swing rods back into the seat back trim cover sleeves. 10. Reaching between the seat back trim cover and the seat back pad, at the middle row of hog rings, position the top of the swing rods under the listing wire in the seat back pad. NOTE: The seat back trim cover has been inverted for clarity. 11. Install new hog rings onto the swing rods (one shown). 12. Pull the seat back rest trim cover completely down and connect the hook and loop fastener to the seat back cushion. 13. Route the seat back heating element wire harness (if equipped). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8490 14. Reattach the seat back trim cover lower J-clips. 15. Position the seat back to the seat bottom and route the wires and cables. 1 Pull the side air bag module wire harness through the seat bottom. 2 Pull the lumbar support cable through the seat bottom. 3 Pull the heated seat wire harness through the seat bottom. 16. Align the seat back to the seat bottom. Install the bolt and tighten to specification. CAUTION: When positioning the seat or installing the bottom to the seat back, be careful not to damage the seat back pivot and any of the wires or cables from the seat back to the seat bottom. This can cause damage to one of the seat components. 17. Install the two bolts and tighten to specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8491 18. Install the push pin onto the side air bag electrical connector. 19. Route the side air bag module electrical connector and wire harness, then install the push pins. 20. Connect the heated seat wire connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8492 21. Route the heated seat wire harness and install the push pin. 22. Connect the lumbar support cable assembly. 1 Install the cable end ball to the cable end retainer. 2 Insert the lumbar cable sleeve into the adjustment cable sleeve slot. 23. Install the push pin holder to the seat bottom frame for the lumbar support cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8493 24. Install the seat bottom lower side shield into the seat bottom frame. 1 Connect the heated seat switch (if equipped). 2 Insert the lower side shield clips into the seat bottom frame. 25. Install the seat bottom lower side shield retaining screw and the lumbar support handle. 26. Connect the power seat switch electrical connector. 27. Position the seat track to the seat bottom frame. Install the four bolts (two shown) and tighten to specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8494 28. Connect the seat motor electrical connector. 29. Install the seat into the vehicle. 30. Connect the battery ground cable. 31. Prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8495 Side Air Bag: Service and Repair Side Air Bag Wiring Harness Limited Seat REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN ON THE COVER TEAR SEAM. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ A side air bag repair is made by installing a new component only. If a part is replaced and the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. ^ Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. ^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. ^ After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Disassemble the seat. For additional information refer to Seat-Front Bucket, 6-Way Power, Except Limited, Seat-Front Bucket, Limited, or Seat-Front Bucket, Manual. NOTE: Be sure to read and follow all air bag warnings in Seat-Front Bucket, 6-Way Power, Except Limited, Seat-Front Bucket, Limited, or Seat-Front Bucket, Disassembly and Assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8496 3. Unhook the trim cover J-clip. WARNING: FRONT SEAT BACK TRIM COVERS INSTALLED ON SEATS EQUIPPED WITH SIDE AIR BAGS CANNOT BE REPAIRED. THEY ARE TO BE REPLACED (CLEANING IS PERMISSIBLE). 4. Roll the seat backrest trim cover to the first row of hog rings. 5. Remove and discard the hog rings. 6. Roll the seat backrest trim cover to the second row of hog rings. 7. Remove and discard the hog rings. 8. Roll the seat backrest trim cover to the side air bag deployment chute. 9. Unzip the side air bag deployment chute. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8497 10. Roll the seat backrest trim cover to the third row of hog rings. 11. Remove and discard the hog rings. 12. Remove the side air bag wiring harness wire tie. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8498 13. Through the seat backrest cushion opening, position the side air bag module aside. ^ Remove the retaining nuts. NOTE: If installing a new side air bag module, use new retaining nuts. If the same side air bag module is to be reused, then reuse the side air bag module retaining nuts. 14. Remove the side air bag module. 1 Release the side air bag module electrical connector clip. 2 Release the connector tabs by pushing in on them, then disconnect the side air bag module electrical connector. 3 Remove the side air bag module. 15. Remove the side air bag wiring harness. ^ Disconnect the pin-type retainers from the seat backrest frame. NOTE: Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8499 ^ Sport bucket seat shown; Limited seat similar. ^ The seat backrest components other than the seat backrest frame and side air bag wiring harness have been omitted for clarity. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE OR ZIPPER, THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY. ^ THE DEPLOYMENT SEAM CANNOT BE REPAIRED OR RESEWN. A TRIM COVER REQUIRING REPLACEMENT OF THE BOLSTER OR SIDE FACING MUST BE REPLACED AS A UNIT. ^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED AND COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Install the side air bag wiring harness. Connect the pin-type retainer to the seat backrest frame. NOTE: ^ The seat backrest components other than the seat backrest frame and side air bag wiring harness have been omitted for clarity. ^ Sport bucket seat shown; Limited seat similar. 2. Connect the side air bag module electrical connector. 1 Install the connector to the side air bag module. 2 Slide the side air bag module electrical connector locking clip to secure the connector to the side air bag module. 3. Make sure the electrical connector is securely fastened to the side air bag module. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8500 4. Install the side air bag module onto the front seat back frame mounting bracket. 1 Position the side air bag module onto the front seat back mounting bracket being sure the side air bag wiring harness is located behind the seat backrest frame. 2 Install the side air bag module retaining nut. WARNING: ^ INSPECT THE MOUNTING SURFACES OF THE SIDE AIR BAG MODULE AND THE SEAT BACK FRAME MOUNTING BRACKET FOR ANY FOREIGN OBJECTS BEFORE INSTALLING THE SIDE AIR BAG MODULE. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ INSPECT THE SIDE AIR BAG DEPLOYMENT CHUTE AND THE SIDE AIR BAG CAVITY IN THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ IF THE AIR BAG COVER HAS SEPARATED OR THE AIR BAG MATERIAL HAS BEEN EXPOSED, INSTALL A NEW SIDE AIR BAG MODULE. DO NOT ATTEMPT TO REPAIR THE AIR BAG MODULE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. CAUTION: ^ The retaining nuts of the side air bag module must be tightened in the sequence described. ^ Be sure the side air bag wiring harness is not pinched between the side air bag module and mounting bracket. 5. Tie-strap the side air bag module wire harness to the seat back frame. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8501 6. Unroll the seat backrest trim cover to the third row of hog rings. 7. Install the hog rings. 8. Roll the seat back trim cover to position the deployment chute around the side air bag module. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8502 9. Position the air bag deployment chute. 1 Insert the outboard side of the air bag deployment chute between the seat back pad and the side air bag module, pulling it around the outboard side of the seat back frame. 2 Insert the inboard side of the air bag deployment chute between the seat back pad and the side air bag module from the inboard side of the seat back. WARNING: ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE OR ZIPPER THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT. ^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED AND COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY. 10. Zip the air bag deployment chute completely closed, then position the zipper tails at the top and bottom of the deployment chute, into the seat back opening. ^ The side air bag deployment chute must encircle the side air bag module, going completely around the side air bag module and the side of the seat back frame. ^ Align the side air bag deployment chute to the side air bag module, making sure it covers the length of the side air bag module. NOTE: ^ Sport bucket seat shown; Limited seat similar. ^ Be sure the side air bag deployment chute is properly positioned, before proceeding to the next step. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8503 11. Unroll the seat backrest trim cover to the second row of hog rings. 12. Install the hog rings. 13. Unroll the seat backrest trim cover to the bottom row of hog rings. 14. Install the hog rings. 15. Hook the trim cover clip. NOTE: If equipped, make sure that the seat backrest heating element wire is aligned with and off-set from the lower seat backrest trim cover J-clip. 16. Assemble the seat. For additional information, refer to Seat-Front Bucket, 6-Way Power, Except Limited and Seat-Front Bucket, Limited. NOTE: Be sure to read and follow all air bag warnings in Seat-Front Bucket, 6-Way Power, Except Limited and Seat-Front Bucket, Limited, Disassembly and Assembly. 17. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 18. Prove out the air bag system. For additional information, refer to Air Bag Systems. 19. Check the restraint system for proper operation. Sport Bucket Seat REMOVAL Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8504 WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN ON THE COVER TEAR SEAM. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ A side air bag repair is made by installing a new component only. If a part is replaced and the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. ^ Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. ^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. ^ After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Disassemble the seat. For additional information, refer to Seat-Front Bucket, 6-Way Power, Except Limited, Seat-Front Bucket, Limited or Seat-Front Bucket. NOTE: Be sure to read and follow all air bag warnings in Seat-Front Bucket, 6-Way Power, Except Limited, Seat-Front Bucket, Limited, or Seat-Front Bucket, Manual, Disassembly and Assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8505 3. Unhook the trim cover J-clip. WARNING: FRONT SEAT BACK TRIM COVERS INSTALLED ON SEATS EQUIPPED WITH SIDE AIR BAGS CANNOT BE REPAIRED. THEY ARE TO BE REPLACED (CLEANING IS PERMISSIBLE). 4. Remove the seat backrest trim cover swing rods. 1 Remove and discard the hog rings. 2 Remove the seat backrest trim cover cushion swing rods. 5. Roll the seatback trim cover in an inside out fashion to the side air bag deployment chute. CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip, or the hook and loop strip can be torn from the seat cushion foam. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8506 6. Unzip the side air bag deployment chute. 7. Roll the seat backrest cover and side air bag deployment chute to completely expose the side air bag bracket and side air bag module. 8. Remove the side air bag wiring harness wire tie. 9. Through the seat backrest cushion opening, position the side air bag module aside. ^ Remove the retaining nuts. NOTE: If installing a new side air bag module, use new retaining nuts. If the same side air bag module is to be reused, then reuse the side air bag module retaining nuts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8507 10. Remove the side air bag module. 1 Release the side air bag module electrical connector clip. 2 Release the connector tabs by pushing in on them, then disconnect the side air bag module electrical connector. 3 Remove the side air bag module. 11. Remove the side air bag wiring harness. ^ Disconnect the pin-type retainers from the seat backrest frame. NOTE: ^ Sport bucket seat shown; Limited seat similar. ^ The seat backrest components other than the seat backrest frame and side air bag wiring harness have been omitted for clarity. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE OR ZIPPER, THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY. ^ THE DEPLOYMENT SEAM CANNOT BE REPAIRED OR RESEWN. A TRIM COVER REQUIRING REPLACEMENT OF THE BOLSTER OR SIDE FACING MUST BE REPLACED AS A UNIT. ^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED AND COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8508 1. Install the side air bag wiring harness. Connect the pin-type retainer to the seat backrest frame. NOTE: ^ The seat backrest components other than the seat backrest frame and side air bag wiring harness have been omitted for clarity. ^ Sport bucket seat shown; Limited seat similar. 2. Connect the side air bag module electrical connector. 1 Install the connector to the side air bag module. 2 Slide the side air bag module electrical connector locking clip to secure the connector to the side air bag module. 3. Make sure the electrical connector is securely fastened to the side air bag module. 4. Install the side air bag module onto the front seat back frame mounting bracket. 1 Position the side air bag module onto the front seat back mounting bracket being sure the side air bag wiring harness is located behind the seat backrest frame. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8509 2 Install the side air bag module retaining nut. WARNING: ^ INSPECT THE MOUNTING SURFACES OF THE SIDE AIR BAG MODULE AND THE SEAT BACK FRAME MOUNTING BRACKET FOR ANY FOREIGN OBJECTS BEFORE INSTALLING THE SIDE AIR BAG MODULE. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ INSPECT THE SIDE AIR BAG DEPLOYMENT CHUTE AND THE SIDE AIR BAG CAVITY IN THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ IF THE AIR BAG COVER HAS SEPARATED OR THE AIR BAG MATERIAL HAS BEEN EXPOSED, INSTALL A NEW SIDE AIR BAG MODULE. DO NOT ATTEMPT TO REPAIR THE AIR BAG MODULE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. CAUTION: ^ The retaining nuts of the side air bag module must be tightened in the sequence described. ^ Be sure the side air bag wiring harness is not pinched between the side air bag module and mounting bracket. 5. Tie-strap the side air bag module wire harness to the seat back frame. 6. Roll the seat back trim cover to position the deployment chute around the side air bag module. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8510 7. Position the air bag deployment chute. 1 Insert the outboard side of the air bag deployment chute between the seat back pad and the side air bag module, pulling it around the outboard side of the seat back frame. 2 Insert the inboard side of the air bag deployment chute between the seat back pad and the side air bag module from the inboard side of the seat back. WARNING: ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE OR ZIPPER THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT. ^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED AND COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY. 8. Zip the air bag deployment chute completely closed, then position the zipper tails at the top and bottom of the deployment chute, into the seat back opening. ^ The side air bag deployment chute must encircle the side air bag module, going completely around the side air bag module and the side of the seat back frame. ^ Align the side air bag deployment chute to the side air bag module, making sure it covers the length of the side air bag module. NOTE: ^ Sport bucket seat shown; Limited seat similar. ^ Be sure the side air bag deployment chute is properly positioned, before proceeding to the next step. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8511 9. If equipped, install the seat backrest trim cover swing rods. 1 Position the seat backrest trim cover and install the swing rods through the sleeves. 2 Install the hog rings. NOTE: Make sure that the top of the swing rod is positioned beneath the listing wire near the middle row of hog rings. 10. Connect the hook and loop fastener to the seat backrest trim cover. 1 Pull the seat backrest trim cover completely down. 2 Reach up inside the seat backrest and grab the plastic above the hook and loop. Remove enough plastic to expose the hook and loop. 11. Hook the trim cover clip. NOTE: If equipped, make sure that the seat backrest heating element wire is aligned with and off-set from the lower seat backrest trim cover J-clip. 12. Assemble the seat. For additional information, refer to Seat-Front Bucket, 6-Way Power, Except Limited and Seat-Front Bucket, Limited. NOTE: Be sure to read and follow all air bag warnings in Seat-Front Bucket, 6-Way Power, Except Limited and Seat-Front Bucket, Limited, Disassembly and Assembly. 13. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 14. Prove out the air bag system. For additional information, refer to Air Bag Systems. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8512 15. Check the restraint system for proper operation. Except Limited and Sport Bucket Seats REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN ON THE COVER TEAR SEAM. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ A side air bag repair is made by installing a new component only. If a part is replaced and the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. ^ Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. ^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. ^ After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Disassemble the seat. For additional information, refer to Seat-Front Bucket, 6-Way Power, Except Limited, Seat-Front Bucket, Limited or Seat-Front Bucket, Manual. NOTE: Be sure to read and follow all air bag warnings in Seat-Front Bucket, 6-Way Power, Except Limited, Seat-Front Bucket, Limited, or Seat-Front Bucket, Manual, Disassembly and Assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8513 3. Unhook the trim cover J-clip. WARNING: FRONT SEAT BACK TRIM COVERS INSTALLED ON SEATS EQUIPPED WITH SIDE AIR BAGS CANNOT BE REPAIRED. THEY ARE TO BE REPLACED (CLEANING IS PERMISSIBLE). 4. Unzip the side air bag deployment chute. 5. Remove the side air bag wiring harness wire tie. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8514 6. Through the seat backrest cushion opening, position the side air bag module aside. ^ Remove the retaining nuts. NOTE: If installing a new side air bag module, use new retaining nuts. If the same side air bag module is to be reused, then reuse the side air bag module retaining nuts. 7. Remove the side air bag module. 1 Release the side air bag module electrical connector clip. 2 Release the connector tabs by pushing in on them, then disconnect the side air bag module electrical connector. 3 Remove the side air bag module. 8. Remove the side air bag wiring harness. ^ Disconnect the pin-type retainers from the seat backrest frame. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8515 NOTE: ^ Sport bucket seat shown; Limited seat similar. ^ The seat backrest components other than the seat backrest frame and side air bag wiring harness have been omitted for clarity. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE OR ZIPPER, THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY. ^ THE DEPLOYMENT SEAM CANNOT BE REPAIRED OR RESEWN. A TRIM COVER REQUIRING REPLACEMENT OF THE BOLSTER OR SIDE FACING MUST BE REPLACED AS A UNIT. ^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED AND COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY. FAILURE TO FOLLOW THESE INSTMCTIONS MAY RESULT IN PERSONAL INJURY. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Install the side air bag wiring harness. ^ Connect the pin-type retainer to the seat backrest frame. NOTE: ^ The seat backrest components other than the seat backrest frame and side air bag wiring harness have been omitted for clarity. ^ Sport bucket seat shown; Limited seat similar. 2. Connect the side air bag module electrical connector. 1 Install the connector to the side air bag module. 2 Slide the side air bag module electrical connector locking clip to secure the connector to the side air bag module. 3. Make sure the electrical connector is securely fastened to the side air bag module. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8516 4. Install the side air bag module onto the front seat back frame mounting bracket. 1 Position the side air bag module onto the front seat back mounting bracket being sure the side air bag wiring harness is located behind the seat backrest frame. 2 Install the side air bag module retaining nut. 3 Install the side air bag module retaining nut. 4 Install the side air bag module retaining nut. WARNING: ^ INSPECT THE MOUNTING SURFACES OF THE SIDE AIR BAG MODULE AND THE SEAT BACK FRAME MOUNTING BRACKET FOR ANY FOREIGN OBJECTS BEFORE INSTALLING THE SIDE AIR BAG MODULE. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ INSPECT THE SIDE AIR BAG DEPLOYMENT CHUTE AND THE SIDE AIR BAG CAVITY IN THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ IF THE AIR BAG COVER HAS SEPARATED OR THE AIR BAG MATERIAL HAS BEEN EXPOSED, INSTALL A NEW SIDE AIR BAG MODULE. DO NOT ATTEMPT TO REPAIR THE AIR BAG MODULE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT. CAUTION: ^ The retaining nuts of the side air bag module must be tightened in the sequence described. ^ Be sure the side air bag wiring harness is not pinched between the side air bag module and mounting bracket. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8517 5. Tie-strap the side air bag module wire harness to the seat back frame. 6. Roll the seat back trim cover to position the deployment chute around the side air bag module. 7. Position the air bag deployment chute. 1 Insert the outboard side of the air bag deployment chute between the seat back pad and the side air bag module, pulling it around the outboard side of the seat back frame. 2 Insert the inboard side of the air bag deployment chute between the seat back pad and the side air bag module from the inboard side of the seat back. WARNING: ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE OR ZIPPER THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT. ^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPELY POSITIONED AND COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Side Air Bag Module > Page 8518 8. Zip the air bag deployment chute completely closed, then position the zipper tails at the top and bottom of the deployment chute, into the seat back opening. ^ The side air bag deployment chute must encircle the side air bag module, going completely around the side air bag module and the side of the seat back frame. ^ Align the side air bag deployment chute to the side air bag module, making sure it covers the length of the side air bag module. NOTE: ^ Sport bucket seat shown; Limited seat similar. ^ Be sure the side air bag deployment chute is properly positioned, before proceeding to the next step. 9. Hook the trim cover clip. NOTE: If equipped, make sure that the seat backrest heating element wire is aligned with and off-set from the lower seat backrest trim cover J-clip. 10. Assemble the seat. For additional information, refer to Seat-Front Bucket, 6-Way Power, Except Limited and Seat-Front Bucket, Limited. NOTE: Be sure to read and follow all air bag warnings in Seat-Front Bucket, 6-Way Power, Except Limited and Seat-Front Bucket, Limited, Disassembly and Assembly. 11. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 12. Prove out the air bag system. For additional information, refer to Air Bag Systems. 13. Check the restraint system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Locations > Page 8522 Malfunction Lamp / Indicator: Description and Operation If an air bag system DTC or malfunction is detected, the air bag indicator is illuminated. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications Air Bag Control Module: Specifications Restraint Control Module Bracket 12 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 8527 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 8528 Air Bag Control Module: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 8529 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 8530 Air Bag Control Module: Description and Operation The Restraints Control Module (RCM) carries out the following functions: ^ signals the inflators to deploy the air bags in the event of a deployable crash. ^ monitors the air bag Supplemental Restraint System (SRS) for faults. ^ illuminates the air bag indicator if a fault is detected. ^ flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected. ^ communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble Codes (DTCs). ^ signals the Generic Electronic Module (GEM) to activate a chime if the air bag indicator is not available and another SRS fault exists. NOTE: The safety sensor is internal to the RCM and is not serviced separately. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the RCM will illuminate the air bag indicator located in the instrument cluster. When the ignition is cycled (turned off and then on), the air bag indicator will prove out by lighting for six seconds and then off for two seconds. After the prove out, the air bag indicator will then flash the two-digit LFC. If an SRS fault exists, the air bag indicator will flash the LFC five times, then it will remain illuminated for the rest of the key cycle. The RCM will also communicate the current and historical DTCs through the DLC, to the scan tool. If the air bag indicator does not function, and the system detects a fault condition, the RCM will signal the GEM to activate an audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed. After that fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors determine that a deployment is required. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation Air Bag Control Module: Service and Repair Removal and Installation REMOVAL WARNING: ^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION IN WHICH THE RIGHT COWL A-PILLAR AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the right hand cowl side trim panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 8533 3. Disconnect the Restraints Control Module (RCM). 1 Slide the two RCM electrical connector locking clips down to disengage them. 2 While squeezing the locking clip area to pivot the latch, disconnect the two RCM electrical connectors. 4. Remove the RCM with bracket. 1 Remove the three RCM bracket retaining bolts. 2 Remove the RCM with bracket. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 8534 1. Follow the removal procedure in reverse order. WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: A repair is made by installing a new part only. If the part does not correct the condition, install the original part and perform the diagnostic procedure again. 2. Prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 8535 Air Bag Control Module: Service and Repair Weld Nut Repair "J" Nut WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both procedures before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J" nuts as outlined in this procedure. Weld nuts must be installed as outlined in Weld Nut Repair- Missing Weld Nut, Restraints Control Module (RCM), Front External Crash and Side Crash Sensor. ^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is in close proximity to the missing weld nut. 1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part numbers: N623342-S101, N800854-S100, N800925-S100). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190) or equivalent. 3. Install the "J" nut through the rectangular hole in the sheet metal. 4. Install the crash sensor. NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet metal. 5. Tighten the attaching screws to specification. Stripped Weld Nut WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455-S190). 2. Drill out the internal threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification. Missing Weld Nut WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 8536 LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both procedures before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J", nuts as outlined in Weld Nut Repair "J" Nut, Restraints Control Module (RCM), Front External Crash and Side Crash Sensor. Weld nuts must be installed as outlined in this procedure. ^ Radiator support repair shown, others are similar. 1. Obtain a 6 mm (0.24 in) weld nut (part number N806285-S190). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-5190). 3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back out an adjacent access hole. 4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5. Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the copper welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole, firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld nut in position. 8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the edge of the weld nut. 9. Metal finish as required. 10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws to specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Warning Relay > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation Seat Belt Warning Relay: Technical Service Bulletins Seat Belts - Warning System Operation Article No. 01-2-5 2/05/01 ^ TRIM - SEAT BELT WARNING SYSTEM - "BELT ^ MINDER" FUNCTION - OPERATION AND SERVICE ^ TIPS ^ ELECTRICAL - SEAT BELT WARNING SYSTEM ^ "BELT MINDER" FUNCTION - OPERATION AND ^ SERVICE TIPS FORD: 2000-2001 CROWN VICTORIA, MUSTANG, TAURUS, EXCURSION, EXPEDITION, F-150, RANGER, WINDSTAR 2001 EXPLORER LINCOLN: 2000-2001 CONTINENTAL, TOWN CAR 2001 LS 2000-2001 NAVIGATOR MERCURY: 2000-2001 GRAND MARQUIS, SABLE 2001 MOUNTAINEER ISSUE The above vehicles have a "Belt Minder" feature that is supplemental to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning light on the instrument cluster. ACTION Some customers may wish to have the Belt Minder deactivated or reactivated. This can be done by performing the deactivation procedure in the Owner Guide (section on Safety Restraints, Belt Minder) or by using the Worldwide Diagnostic System (WDS) tool and performing the following Service Procedure. SERVICE PROCEDURE To deactivate or reactivate the Belt Minder using the WDS tool, refer to the following procedure. 1. Establish a session for the vehicle. 2. Select the "Toolbox" icon. 3. Select "Module Programming" and press the "Tick" mark. 4. Select "Programmable Parameters", then "Warning Lamps/Chimes" and press the "Tick" mark. 5. Select "Beltminder - (HEC)", then select "Enabled or Disabled" and press the "Tick" mark. 6. WDS will display "Configuration Complete", then press the "Tick" mark. NOTE: IF THE DRIVER'S SAFETY BELT IS NOT BUCKLED BEFORE THE VEHICLE HAS REACHED AT LEAST 5 KM/H (3 MPH) AND 1-2 MINUTES HAVE ELAPSED SINCE THE IGNITION SWITCH HAS BEEN TURNED ON, THEN THE BELT MINDER WILL ILLUMINATE THE SAFETY BELT WARNING LIGHT AND WILL SOUND THE SAFETY BELT WARNING CHIME FOR 6 SECONDS EVERY 30 SECONDS, REPEATING FOR APPROXIMATELY 5 MINUTES OR UNTIL THE SAFETY BELT IS BUCKLED. NOTE: WHEN THE BELT MINDER IS DEACTIVATED, THE SAFETY BELT WARNING LIGHT AND CHIME WILL CONTINUE TO OPERATE NORMALLY. THE SAFETY BELT WARNING LIGHT WILL REMAIN ILLUMINATED FOR 1-2 MINUTES AND THE WARNING CHIME WILL SOUND FOR 4-8 SECONDS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Warning Relay > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation > Page 8541 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 104000, 204000, 206000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING:To reduce the risk of personal injury, do not use any memory saver devices. NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram See: Air Bag Systems. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8547 7. Remove the two steering wheel back cover plugs. 8. Remove the two driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. 10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical connector at the clockspring. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8548 11. Open the glove compartment door to access the passenger air bag module mounting screws. 12. Remove the two screws. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove box opening, push out on the passenger air bag module and separate it from the instrument panel. 14. Disconnect the electrical connector and remove the passenger air bag module. 15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the passenger air bag module electrical connector. Vehicles equipped with seat side air bags Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8549 16. Disconnect the passenger seat side air bag module electrical connector located under the passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector located under the driver seat. 19. Connect the restraint system diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical connector. All vehicles 20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground cable. Reactivation Procedure All vehicles 1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles equipped with seat side air bags 3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side air bag module electrical connector located under the driver seat. 4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint system diagnostic tool from the body harness side of the passenger seat side air bag module electrical connector located under the passenger seat. 6. Connect the passenger seat side air bag module electrical connector All vehicles 7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air bag module electrical connector. 8. Install the passenger air bag module. 9. Connect the passenger air bag module electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8550 10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical connector at the clockspring. 11. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag module to the steering wheel. 12. Install the two driver air bag module retaining bolts. 13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON. 15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 17. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8551 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle battery connected? Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8552 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Prove out the system means to turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation Child Seat Tether Attachment: Description and Operation Attaching Safety Seats With Tether Straps Some manufacturers make child safety seats that include a tether strap that goes over the back of the vehicle seat and attaches to an anchoring point. Other manufacturers offer the tether strap as an accessory. Contact the manufacturer of the child safety seat for information about ordering a tether strap. Attach a tether strap anchor bracket to the rear floor by using a tether anchor kit, available at no charge from any Ford or Lincoln-Mercury dealership. Carefully read and follow the instructions provided with the kit for installation of the child tether strap anchor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Specifications Seat Belt: Specifications Rear Seat Center Occupant Safety Belt And Retractor Bolt 40 Nm Safety Belt Anchor Bolts 40 Nm Safety Belt Guide To Floor Bolt 40 Nm Safety Belt Guide To Seat Track Bolt 9.0 Nm Safety Belt Guide To Seat Track Nut 9.0 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Safety Belt Cleaning Seat Belt: Service and Repair Safety Belt Cleaning 1. Clean the safety belt webbing only with a mild soap solution recommended for cleaning upholstery or carpets. Follow the instructions provided with the soap. WARNING: DO NOT BLEACH OR RE-DYE THE WEBBING, AS THE WEBBING MAY WEAKEN. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Safety Belt Cleaning > Page 8562 Seat Belt: Service and Repair Safety 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 10.7 mm (27/64 in) drill. 3. Rethread the anchor plate with a 1/2-13 tap (seat belt). 4. Clean out the chips. 5. Install the attachment parts. Original parts are to be replaced with the repair parts indicated in the Safety Belt Parts Replacement Guidelines. See: Parts Replacement Chart 6. When repairing a multiple belt and attachment, install the nut to the bolt in the tunnel area from the underside of the floorpan. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Safety Belt Cleaning > Page 8563 Seat Belt: Service and Repair Replacement Of The Weld Nut And Reinforcement 1. Remove the interior trim panel to expose the suspect anchor point. 2. Determine if the weld nut only or the weld nut and reinforcement and weld nut are missing. If the B or C- or D- pillar safety belt anchor nuts or reinforcements are stripped or missing, they should be replaced with a new nut or reinforcement. To install a missing weld nut only, proceed to Step 3. 3. Obtain a M12 weld nut and a standard washer. 4. Drill out two 8 mm (5/16 in) diameter holes adjacent to the clearance hole. 5. Obtain a length of copper welding wire and feed through clearance hole in door frame opening until it becomes visible at the access hole. 6. Pull the wire through so that it may be secured to the weld nut and washer. 7. Pull the wire back up to the weld nut clearance bole. 8. Hold the weld nut securely in place. Use the MIG Wire Feed Welder 106-00053 to plug weld the nut in place at the two 8 mm (5/16 in)diameter holes previously drilled. 9. Metal finish as required. 10. Verify the nut is securely in place. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Safety Belt Cleaning > Page 8564 Seat Belt: Service and Repair Safety Belt Shoulder Height Adjuster With Stripped Weld Nuts D-Ring Installation Kit SPECIAL SERVICE TOOLS 1. Remove the B-pillar trim panel. 2. Use the half-inch drill with integral stop provided in D-Ring Installation Kit to drill out the damaged threads in the upper pillar structure. 3. Apply a suitable lubricant to the M14 x 1.5 tap with integral stop provided in D-Ring Installation Kit and tap new threads. NOTE: After each rotation, back off tap slightly to remove new cuttings and be sure to blow out any chips before proceeding. 4. Use a threaded insert (N807170-S190) provided in the D-Ring Installation Kit and screw it into the retapped hole until it is slightly below the surface. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Safety Belt Cleaning > Page 8565 5. Use a hammer to lightly tap the installation tool provided in the D-Ring Installation Kit several times to seat the insert keys. NOTE: If the two bolts on the height adjuster are not stripped, install the height adjuster. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Safety Belt Cleaning > Page 8566 Seat Belt: Service and Repair Safety Belt Cleaning 1. Clean the safety belt webbing only with a mild soap solution recommended for cleaning upholstery or carpets. Follow the instructions provided with the soap. WARNING: DO NOT BLEACH OR RE-DYE THE WEBBING, AS THE WEBBING MAY WEAKEN. Safety 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 10.7 mm (27/64 in) drill. 3. Rethread the anchor plate with a 1/2-13 tap (seat belt). 4. Clean out the chips. 5. Install the attachment parts. Original parts are to be replaced with the repair parts indicated in the Safety Belt Parts Replacement Guidelines. See: Parts Replacement Chart 6. When repairing a multiple belt and attachment, install the nut to the bolt in the tunnel area from the underside of the floorpan. Replacement Of The Weld Nut And Reinforcement 1. Remove the interior trim panel to expose the suspect anchor point. 2. Determine if the weld nut only or the weld nut and reinforcement and weld nut are missing. If the B or C- or D- pillar safety belt anchor nuts or reinforcements are stripped or missing, they should be replaced with a new nut or reinforcement. To install a missing weld nut only, proceed to Step 3. 3. Obtain a M12 weld nut and a standard washer. 4. Drill out two 8 mm (5/16 in) diameter holes adjacent to the clearance hole. 5. Obtain a length of copper welding wire and feed through clearance hole in door frame opening until it becomes visible at the access hole. 6. Pull the wire through so that it may be secured to the weld nut and washer. 7. Pull the wire back up to the weld nut clearance bole. 8. Hold the weld nut securely in place. Use the MIG Wire Feed Welder 106-00053 to plug weld the nut in place at the two 8 mm (5/16 in)diameter holes previously drilled. 9. Metal finish as required. 10. Verify the nut is securely in place. Safety Belt Shoulder Height Adjuster With Stripped Weld Nuts D-Ring Installation Kit SPECIAL SERVICE TOOLS 1. Remove the B-pillar trim panel. 2. Use the half-inch drill with integral stop provided in D-Ring Installation Kit to drill out the damaged threads in the upper pillar structure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Safety Belt Cleaning > Page 8567 3. Apply a suitable lubricant to the M14 x 1.5 tap with integral stop provided in D-Ring Installation Kit and tap new threads. NOTE: After each rotation, back off tap slightly to remove new cuttings and be sure to blow out any chips before proceeding. 4. Use a threaded insert (N807170-S190) provided in the D-Ring Installation Kit and screw it into the retapped hole until it is slightly below the surface. 5. Use a hammer to lightly tap the installation tool provided in the D-Ring Installation Kit several times to seat the insert keys. NOTE: If the two bolts on the height adjuster are not stripped, install the height adjuster. Safety Belt Tongue Rotated on Belt 1. Fold the safety belt as indicated. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Safety Belt Cleaning > Page 8568 2. Pull the safety belt tongue over the fold in the safety belt. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Specifications Seat Belt Buckle: Specifications Driver Seat Safety Belt Buckle Nut 40 Nm Front Seat Safety Belt Buckle Bolt 40 Nm Rear Seat Safety Belt Buckle Assembly Rear Nuts 48 Nm Rear Seat Safety Belt Buckle Front Nuts 40 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Specifications > Page 8572 Seat Belt Buckle: Locations Buckles, Four-Door Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Specifications > Page 8573 Buckles, Two-Door Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Specifications > Page 8574 Seat Belt Buckle: Description and Operation When replacing safety belt buckle or retractor assemblies, use only the replacement parts specified in the Ford Customer Service Division Master Parts Catalog. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Bucket Seats Seat Belt Buckle: Service and Repair Bucket Seats Safety Belt Bolt Bit SPECIAL SERVICE TOOLS REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS 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. 1. Remove the floor console. 2. Move the seat forward and use Safety Belt Bolt Bit to remove the slide bar bolt. 3. Remove the front seat. 4. Remove the safety belt slide bar. 1 Disconnect the electrical connector (LH only). 2 Remove the nut. 3 Remove the bolt. 4 Remove the slide bar. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Bucket Seats > Page 8577 5. Remove the safety belt buckle. 1 Clamp the slide bar in a suitable vise. 2 Use Safety Belt Bolt Bit to remove the bolt. 3 Remove the buckle. NOTE: Clamp the slide bar collar in a vise along the break line only. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Bucket Seats > Page 8578 Seat Belt Buckle: Service and Repair Rear Seat Four-Door REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS 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. 1. Remove the rear seats. 2. Remove the rear safety belt buckle assembly. 1 Remove the nuts. 2 Remove the rear safety belt buckle assembly. INSTALLATION 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. Two-Door REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS 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. 1. Remove the rear seats. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Bucket Seats > Page 8579 2. Remove the rear safety belt buckles. 1 Remove the nuts. 2 Remove the rear safety belt buckles. INSTALLATION 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Description and Operation Seat Belt Extension: Description and Operation In certain cases, the safety belt may be too short even when it is fully extended. About 20 cm (8 in) can be added to the belt length by using a safety belt extension. Safety belt extensions are available at no cost from any Ford or Lincoln-Mercury dealer parts department. Safety belt extensions are only available with black webbing. There are two extension assemblies available, one for the front seating positions and one for the rear seating positions and they are not interchangeable. Use only extensions manufactured by the same supplier as the safety belt. Manufacturer identification is located at the end of the webbing on the label. Also, use the safety belt extension only if safety belt is too short for you when fully extended. Do not use extension to change the fit of the shoulder belt across the torso. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Specifications Seat Belt Height Adjuster: Specifications Shoulder Safety Belt Height Adjuster Bolts 40 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal and Installation Seat Belt Height Adjuster: Service and Repair Removal and Installation Four-Door Safety Belt Bolt Bit SPECIAL SERVICE TOOLS REMOVAL 1. Remove the B-pillar trim panel. 2. Remove the height adjuster cover. 3. Remove the shoulder safety belt height adjuster. 1 Use Safety Belt Bolt Bit to remove the two bolts. 2 Remove the shoulder safety belt height adjuster. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal and Installation > Page 8588 1. Use Safety Belt Bolt Bit and install the shoulder safety belt height adjuster. 2. Install the height adjuster cover. 3. Install the B-pillar trim panel. 4. Check the restraint system for proper operation. Two-Door Safety Belt Bolt Bit SPECIAL SERVICE TOOLS REMOVAL 1. Remove the quarter trim panel. 2. Remove the height adjuster cover. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal and Installation > Page 8589 3. Remove the shoulder safety belt height adjuster. 1 Use Safety Belt Bolt Bit to remove the two bolts. 2 Remove the shoulder safety belt height adjuster. INSTALLATION 1. Use Safety Belt Bolt Bit and install the shoulder safety belt height adjuster. 2. Install the height adjuster cover. 3. Install the quarter trim panel. 4. Check the restraint system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal and Installation > Page 8590 Seat Belt Height Adjuster: Service and Repair General Procedures D-Ring Installation Kit SPECIAL SERVICE TOOLS 1. Remove the B-pillar trim panel. 2. Use the half-inch drill with integral stop provided in D-Ring Installation Kit to drill out the damaged threads in the upper pillar structure. 3. Apply a suitable lubricant to the M14 x 1.5 tap with integral stop provided in D-Ring Installation Kit and tap new threads. NOTE: After each rotation, back off tap slightly to remove new cuttings and be sure to blow out any chips before proceeding. 4. Use a threaded insert (N807170-S190) provided in the D-Ring Installation Kit and screw it into the retapped hole until it is slightly below the surface. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal and Installation > Page 8591 5. Use a hammer to lightly tap the installation tool provided in the D-Ring Installation Kit several times to seat the insert keys. NOTE: If the two bolts on the height adjuster are not stripped, install the height adjuster. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Locations > Page 8595 Seat Belt Reminder Lamp: Description and Operation The safety belt warning indicator is powered through the GEM/CTM module. When the ignition key is turned on, the indicator illuminates for four to eight seconds even if the safety belt is buckled. For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Locations > Page 8596 Seat Belt Reminder Lamp: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints - Seat Belts Slow to Retract Seat Belt Retractor: Customer Interest Restraints - Seat Belts Slow to Retract TSB 05-16-11 08/22/05 SAFETY BELT RETRACTION SPEED FORD: 2000-2003 Mustang 2000-2006 Crown Victoria, Taurus 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion, Explorer 2000-2006 E-Series, Expedition, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2004-2006 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 LS, Town Car, Navigator 2003-2005 Aviator MERCURY: 2000-2005 Sable 2000-2006 Grand Marquis 2000-2005 Mountaineer 2004-2006 Monterey 2005-2006 Mariner This article supersedes TSB 04-24-21 to update the vehicle model years. ISSUE A service kit is now available to improve safety belt retraction speed. ACTION See the part application chart and select the appropriate kit. Follow the Instruction Sheet included in the kit. Refer to Workshop Manual Section 501-20A for additional information. NOTE TEFLON TAPE SHOULD ONLY BE USED ON THE FRONT ROW SEATS FOR VEHICLES LISTED IN THIS TSB, WITH THE EXCEPTION OF THE AVIATOR, EXPLORER 4DR AND THE MOUNTAINEER. TEFLON TAPE CAN ALSO BE USED ON SECOND ROW SEATS FOR THESE THREE VEHICLES. NOTE FOR MUSTANG, AVIATOR, EXPLORER 4DR AND MOUNTAINEER, REFER TO THE FOLLOWING BUILD DATE INFORMATION BEFORE PERFORMING THIS TSB. TEFLON TAPE HAS ALREADY BEEN INSTALLED DURING PRODUCTION ON SOME OF THESE VEHICLES. ^ MUSTANG: Only install on vehicles built through 6/15/2003. Teflon tape was already installed on vehicles built on/after 6/16/2003. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (FRONT ROW SEATS): Only install on vehicles built through 6/24/2004. Teflon tape was already installed on vehicles built on/after 6/25/2004. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (SECOND ROW SEATS): Only install on vehicles built through 10/21/2004. Teflon tape was already installed on vehicles built on/after 10/22/2004. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints - Seat Belts Slow to Retract > Page 8605 Parts Block NOTE THE LABOR OPERATIONS WITHIN THIS TSB CAN BE CLAIMED IN COMBINATION AS NEEDED TO COVER THE REQUIRED REPAIRS. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051611A Install Teflon Tape B 0.8 Hr. Pillars Both Sides (Includes Time To Remove And Install Trim Panels If Necessary) 051611B Install Teflon Tape C 1.1 Hrs. Pillars Both Sides (Includes Time To Remove And Install Trim Panels And Seats If Necessary) DEALER CODING CONDITION BASIC PART NO. CODE 70611B08 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints Seat Belts Slow to Retract Seat Belt Retractor: All Technical Service Bulletins Restraints - Seat Belts Slow to Retract TSB 05-16-11 08/22/05 SAFETY BELT RETRACTION SPEED FORD: 2000-2003 Mustang 2000-2006 Crown Victoria, Taurus 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion, Explorer 2000-2006 E-Series, Expedition, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2004-2006 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 LS, Town Car, Navigator 2003-2005 Aviator MERCURY: 2000-2005 Sable 2000-2006 Grand Marquis 2000-2005 Mountaineer 2004-2006 Monterey 2005-2006 Mariner This article supersedes TSB 04-24-21 to update the vehicle model years. ISSUE A service kit is now available to improve safety belt retraction speed. ACTION See the part application chart and select the appropriate kit. Follow the Instruction Sheet included in the kit. Refer to Workshop Manual Section 501-20A for additional information. NOTE TEFLON TAPE SHOULD ONLY BE USED ON THE FRONT ROW SEATS FOR VEHICLES LISTED IN THIS TSB, WITH THE EXCEPTION OF THE AVIATOR, EXPLORER 4DR AND THE MOUNTAINEER. TEFLON TAPE CAN ALSO BE USED ON SECOND ROW SEATS FOR THESE THREE VEHICLES. NOTE FOR MUSTANG, AVIATOR, EXPLORER 4DR AND MOUNTAINEER, REFER TO THE FOLLOWING BUILD DATE INFORMATION BEFORE PERFORMING THIS TSB. TEFLON TAPE HAS ALREADY BEEN INSTALLED DURING PRODUCTION ON SOME OF THESE VEHICLES. ^ MUSTANG: Only install on vehicles built through 6/15/2003. Teflon tape was already installed on vehicles built on/after 6/16/2003. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (FRONT ROW SEATS): Only install on vehicles built through 6/24/2004. Teflon tape was already installed on vehicles built on/after 6/25/2004. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (SECOND ROW SEATS): Only install on vehicles built through 10/21/2004. Teflon tape was already installed on vehicles built on/after 10/22/2004. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints Seat Belts Slow to Retract > Page 8611 Parts Block NOTE THE LABOR OPERATIONS WITHIN THIS TSB CAN BE CLAIMED IN COMBINATION AS NEEDED TO COVER THE REQUIRED REPAIRS. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051611A Install Teflon Tape B 0.8 Hr. Pillars Both Sides (Includes Time To Remove And Install Trim Panels If Necessary) 051611B Install Teflon Tape C 1.1 Hrs. Pillars Both Sides (Includes Time To Remove And Install Trim Panels And Seats If Necessary) DEALER CODING CONDITION BASIC PART NO. CODE 70611B08 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Page 8612 Seat Belt Retractor: Specifications Rear Seat Center Occupant Safety Belt And Retractor Bolt 40 Nm Safety Belt Retractor Bolts 40 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Page 8613 Seat Belt Retractor: Description and Operation The shoulder harness retractor is designed to let the webbing move freely in or out at all times, except during vehicle hard braking, hard cornering or an impact of 8 km/h (5 mph) or more, when it is automatically locked by a mechanically actuated inertia sensor. DUAL LOCKING MODE RETRACTORS NOTE: When replacing a dual locking mode retractor, the retractor should be checked to make sure it is not in the Automatic Locking Retractor (ALR) mode after installation in the stowed position. All outboard continuous-loop, three-point retractor systems, except the driver position, are equipped with the dual locking mode system. The Emergency Locking Retractor (ELR) mode will allow the occupant freedom of movement, locking tight only on hard braking, hard cornering, or an impact of approximately 8 km/h (5 mph). The ELR mode helps to reduce the forward movement of the driver and passengers. The ELR mode is continuously in operation at all seating positions. The ALR portion of this system does not allow the occupant freedom of movement. The ALR mode is used when locking a child seat in an outboard seating position or when a tight belt fit is desired. The ALR mode is disengaged when the webbing is free to move in or out of the retractor. The ALR mode is automatically engaged when the webbing is fully extracted from the retractor and then allowed to retract. As the webbing is retracted back onto the spool, an audible clicking sound is made, indicating that the retractor is in ALR mode. The ALR mode is automatically disengaged when most of the webbing is retracted back onto the spool. WARNING: AFTER ANY VEHICLE COLLISION, THE SAFETY BELT SYSTEM AT ALL OUTBOARD SEATING POSITIONS (EXCEPT DRIVER, WHICH HAS NO "AUTOMATIC LOCKING RETRACTOR" FEATURE) MUST BE CHECKED BY A QUALIFIED TECHNICIAN TO VERIFY THAT THE "AUTOMATIC LOCKING RETRACTOR" FEATURE FOR CHILD SEATS IS STILL FUNCTIONING PROPERLY, IN ADDITION TO OTHER CHECKS FOR PROPER SAFETY BELT SYSTEM FUNCTION. A BELT AND RETRACTOR ASSEMBLY MUST BE REPLACED IF THE SAFETY BELT ASSEMBLY'S "AUTOMATIC LOCKING RETRACTOR" FEATURE OR ANY OTHER SAFETY BELT FUNCTION IS NOT OPERATING PROPERLY WHEN CHECKED ACCORDING TO THE PROCEDURES IN THE WORKSHOP MANUAL. FAILURE TO REPLACE THE BELT AND RETRACTOR ASSEMBLY COULD INCREASE THE RISK OF INJURY IN COLLISIONS. This vehicle has a safety belt system with an energy management feature at the front seating positions to help further reduce the risk of injury in the event of a head-on collision. This safety belt system has a retractor assembly that is designed to pay out webbing in a controlled manner. This feature is designed to help reduce the belt force acting on occupant's chest. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Page 8614 Seat Belt Retractor: Testing and Inspection WARNING: AFTER ANY VEHICLE COLLISION, THE SAFETY BELT SYSTEM AT ALL OUTBOARD SEATING POSITIONS (EXCEPT DRIVER, WHICH HAS NO "AUTOMATIC LOCKING RETRACTOR" FEATURE) MUST BE CHECKED BY A QUALIFIED TECHNICIAN TO VERIFY THAT THE "AUTOMATIC LOCKING RETRACTOR" FEATURE FOR CHILD SEATS IS STILL FUNCTIONING PROPERLY, IN ADDITION TO OTHER CHECKS FOR PROPER SAFETY BELT SYSTEM FUNCTION. A BELT AND RETRACTOR ASSEMBLY MUST BE REPLACED IF THE SAFETY BELT ASSEMBLY'S "AUTOMATIC LOCKING RETRACTOR" FEATURE, OR ANY OTHER SAFETY BELT FUNCTION, IS NOT OPERATING PROPERLY WHEN CHECKED ACCORDING TO THE PROCEDURES IN THE WORKSHOP MANUAL. FAILURE TO REPLACE THE BELT AND RETRACTOR ASSEMBLY COULD INCREASE THE RISK OF INJURY IN COLLISIONS. 1. Extend the safety belt to latch the tongue into the buckle across an empty seat without slack in the safety belt, with the seat in the full down and rearmost position, seat back in an upright position, and if applicable, the D-ring adjusted in the full down position. 2. Pull the shoulder belt to full extension to engage the retractor's Automatic Locking Retractor (ALR) feature. Then allow the belt to retract freely in the ALR mode, and the retractor force set the proper belt tightness. 3. Pull on the shoulder belt to check that the belt has remained in the ALR mode. If the belt is not locked, install a new belt and retractor assembly. The safety belt should remain locked in the ALR mode across an empty seat. 4. To verify that the safety belt still automatically disengages from the ALR mode properly, with the D-ring adjusted to the full up position, if applicable, unlatch the safety belt tongue from the buckle and allow the safety belt to retract to its stowed position. Pull on the shoulder belt to verify that the retractor assembly has converted automatically out of the ALR mode. If the belt remains locked in the stowed position, a new belt and retractor assembly must be installed. The safety belt should extract freely. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > B-Pillar Retractor Seat Belt Retractor: Service and Repair B-Pillar Retractor Two-Door Safety Belt Bolt Bit SPECIAL SERVICE TOOLS REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS 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. 1. Remove the quarter trim panel. 2. Remove the front safety belt retractor. 1 Use Safety Belt Bolt Bit to remove the bolt. 2 Remove the front safety belt retractor. INSTALLATION 1. Use Safety Belt Bolt Bit to install the front safety belt retractor. 2. Install the quarter trim panel. 3. Check the restraint system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > B-Pillar Retractor > Page 8617 Driver Side and Outside Passenger,Four-Door Safety Belt Bolt Bit SPECIAL SERVICE TOOLS REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS 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. 1. Remove the B-pillar trim panel. 2. Remove the front safety belt retractor. 1 Use Safety Belt Bolt Bit to remove the bolts. 2 Remove the front safety belt retractor. INSTALLATION 1. Use Safety Belt Bolt Bit to install the front safety belt retractor. 2. Install the B-pillar trim panel. 3. Check the restraint system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > B-Pillar Retractor > Page 8618 Seat Belt Retractor: Service and Repair C-Pillar Retractor Four-Door Safety Belt Bolt Bit SPECIAL SERVICE TOOLS REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS 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. 1. Remove the quarter trim panel. 2. Remove the safety belt retractor. 1 Use Safety Belt Bolt Bit to remove the bolt. 2 Remove the safety belt retractor. INSTALLATION 1. Use Safety Belt Bolt Bit to install the safety belt retractor. 2. Install the quarter trim panel. 3. Check the restraint system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > B-Pillar Retractor > Page 8619 Two-Door Safety Belt Bolt Bit SPECIAL SERVICE TOOLS REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS 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. 1. Remove the quarter trim panel. 2. Remove the safety belt retractor. 1 Use Safety Belt Bolt Bit to remove the bolts. 2 Remove the safety belt retractor. INSTALLATION 1. Use Safety Belt Bolt Bit to install the safety belt retractor. 2. Install the quarter trim panel. 3. Check the restraint system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > B-Pillar Retractor > Page 8620 Seat Belt Retractor: Service and Repair Rear Seat Retractor and Buckle Assembly, Four-Door Safety Belt Bolt Bit SPECIAL SERVICE TOOLS REMOVAL WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS 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. 1. Fold the rear seat down to load floor position. 2. Remove the rear safety belt buckle and retractor assembly. 1 Use Safety Belt Bolt Bit to remove the bolt. 2 Remove the rear safety belt buckle and retractor assembly. INSTALLATION 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. NOTE: Make sure the safety belt webbing is not twisted prior to installation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Warning Relay > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation Seat Belt Warning Relay: Technical Service Bulletins Seat Belts - Warning System Operation Article No. 01-2-5 2/05/01 ^ TRIM - SEAT BELT WARNING SYSTEM - "BELT ^ MINDER" FUNCTION - OPERATION AND SERVICE ^ TIPS ^ ELECTRICAL - SEAT BELT WARNING SYSTEM ^ "BELT MINDER" FUNCTION - OPERATION AND ^ SERVICE TIPS FORD: 2000-2001 CROWN VICTORIA, MUSTANG, TAURUS, EXCURSION, EXPEDITION, F-150, RANGER, WINDSTAR 2001 EXPLORER LINCOLN: 2000-2001 CONTINENTAL, TOWN CAR 2001 LS 2000-2001 NAVIGATOR MERCURY: 2000-2001 GRAND MARQUIS, SABLE 2001 MOUNTAINEER ISSUE The above vehicles have a "Belt Minder" feature that is supplemental to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning light on the instrument cluster. ACTION Some customers may wish to have the Belt Minder deactivated or reactivated. This can be done by performing the deactivation procedure in the Owner Guide (section on Safety Restraints, Belt Minder) or by using the Worldwide Diagnostic System (WDS) tool and performing the following Service Procedure. SERVICE PROCEDURE To deactivate or reactivate the Belt Minder using the WDS tool, refer to the following procedure. 1. Establish a session for the vehicle. 2. Select the "Toolbox" icon. 3. Select "Module Programming" and press the "Tick" mark. 4. Select "Programmable Parameters", then "Warning Lamps/Chimes" and press the "Tick" mark. 5. Select "Beltminder - (HEC)", then select "Enabled or Disabled" and press the "Tick" mark. 6. WDS will display "Configuration Complete", then press the "Tick" mark. NOTE: IF THE DRIVER'S SAFETY BELT IS NOT BUCKLED BEFORE THE VEHICLE HAS REACHED AT LEAST 5 KM/H (3 MPH) AND 1-2 MINUTES HAVE ELAPSED SINCE THE IGNITION SWITCH HAS BEEN TURNED ON, THEN THE BELT MINDER WILL ILLUMINATE THE SAFETY BELT WARNING LIGHT AND WILL SOUND THE SAFETY BELT WARNING CHIME FOR 6 SECONDS EVERY 30 SECONDS, REPEATING FOR APPROXIMATELY 5 MINUTES OR UNTIL THE SAFETY BELT IS BUCKLED. NOTE: WHEN THE BELT MINDER IS DEACTIVATED, THE SAFETY BELT WARNING LIGHT AND CHIME WILL CONTINUE TO OPERATE NORMALLY. THE SAFETY BELT WARNING LIGHT WILL REMAIN ILLUMINATED FOR 1-2 MINUTES AND THE WARNING CHIME WILL SOUND FOR 4-8 SECONDS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Warning Relay > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation > Page 8625 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 104000, 204000, 206000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Warning Timer > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation Seat Belt Warning Timer: Technical Service Bulletins Seat Belts - Warning System Operation Article No. 01-2-5 2/05/01 ^ TRIM - SEAT BELT WARNING SYSTEM - "BELT ^ MINDER" FUNCTION - OPERATION AND SERVICE ^ TIPS ^ ELECTRICAL - SEAT BELT WARNING SYSTEM ^ "BELT MINDER" FUNCTION - OPERATION AND ^ SERVICE TIPS FORD: 2000-2001 CROWN VICTORIA, MUSTANG, TAURUS, EXCURSION, EXPEDITION, F-150, RANGER, WINDSTAR 2001 EXPLORER LINCOLN: 2000-2001 CONTINENTAL, TOWN CAR 2001 LS 2000-2001 NAVIGATOR MERCURY: 2000-2001 GRAND MARQUIS, SABLE 2001 MOUNTAINEER ISSUE The above vehicles have a "Belt Minder" feature that is supplemental to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning light on the instrument cluster. ACTION Some customers may wish to have the Belt Minder deactivated or reactivated. This can be done by performing the deactivation procedure in the Owner Guide (section on Safety Restraints, Belt Minder) or by using the Worldwide Diagnostic System (WDS) tool and performing the following Service Procedure. SERVICE PROCEDURE To deactivate or reactivate the Belt Minder using the WDS tool, refer to the following procedure. 1. Establish a session for the vehicle. 2. Select the "Toolbox" icon. 3. Select "Module Programming" and press the "Tick" mark. 4. Select "Programmable Parameters", then "Warning Lamps/Chimes" and press the "Tick" mark. 5. Select "Beltminder - (HEC)", then select "Enabled or Disabled" and press the "Tick" mark. 6. WDS will display "Configuration Complete", then press the "Tick" mark. NOTE: IF THE DRIVER'S SAFETY BELT IS NOT BUCKLED BEFORE THE VEHICLE HAS REACHED AT LEAST 5 KM/H (3 MPH) AND 1-2 MINUTES HAVE ELAPSED SINCE THE IGNITION SWITCH HAS BEEN TURNED ON, THEN THE BELT MINDER WILL ILLUMINATE THE SAFETY BELT WARNING LIGHT AND WILL SOUND THE SAFETY BELT WARNING CHIME FOR 6 SECONDS EVERY 30 SECONDS, REPEATING FOR APPROXIMATELY 5 MINUTES OR UNTIL THE SAFETY BELT IS BUCKLED. NOTE: WHEN THE BELT MINDER IS DEACTIVATED, THE SAFETY BELT WARNING LIGHT AND CHIME WILL CONTINUE TO OPERATE NORMALLY. THE SAFETY BELT WARNING LIGHT WILL REMAIN ILLUMINATED FOR 1-2 MINUTES AND THE WARNING CHIME WILL SOUND FOR 4-8 SECONDS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Warning Timer > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation > Page 8630 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 104000, 204000, 206000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Side Crash Sensor 12 Nm Front Crash Sensor 10.2-13.8 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Driver Side Air Bag Crash Sensor Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Driver Side Air Bag Crash Sensor > Page 8637 Impact Sensor: Locations Front Crash Sensors Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Driver Side Air Bag Crash Sensor > Page 8638 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Driver Side Air Bag Crash Sensor > Page 8639 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Driver Side Air Bag Crash Sensor > Page 8640 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front External Crash Sensor Impact Sensor: Service and Repair Front External Crash Sensor REMOVAL WARNING: ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: A repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the radiator grill and radiator opening cover. 3. Remove the air bag sensor. 1 Disconnect the air bag sensor electrical connector. 2 Remove the three screws. 3 Remove the air bag sensor. INSTALLATION WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: A repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front External Crash Sensor > Page 8643 1. Follow the removal procedure in reverse order. 2. Prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front External Crash Sensor > Page 8644 Impact Sensor: Service and Repair Side Crash Sensor REMOVAL WARNING: ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. ^ Right side is shown, left side is similar. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the B-pillar lower trim panel with scuff plates. NOTE: ^ Four door is shown, two door is similar. ^ The front seat has been removed for clarity. 3. Remove the side crash sensor. 1 Disconnect the side crash sensor electrical connector. 2 Remove the two retaining bolts. 3 Remove the side crash sensor with bracket. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front External Crash Sensor > Page 8645 WARNING: ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Follow the removal procedure in reverse order. 2. Prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Accessory Delay Relay: Locations The Generic Electronic Module (GEM) / Central Timer Module (CTM) Controls the Accessory Delay Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8651 Accessory Delay Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Control Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Control Module > Component Information > Locations > Page 8656 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Motor > Component Information > Service and Repair Antenna Motor: Service and Repair REMOVAL NOTE: The antenna motor and the antenna cable is removed as an assembly. 1. Disconnect the battery ground cable. 2. Unsnap the radio antenna base cap. 3. Remove the radio antenna nut. 4. Remove the front fender apron. 1 Remove the screws. 2 Remove the bolts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Motor > Component Information > Service and Repair > Page 8663 5. Remove lower antenna mounting screw. 6. Remove the RH cowl side trim panel. 7. Disconnect the antenna motor electrical connector. 8. Remove the audio unit. For additional information, refer to Radio, Stereo, and Compact Disc. 9. Position the antenna lead in cable into the engine compartment. 1 Open the glove compartment door. 2 Release the tabs and lower the glove compartment to the full open position. 3 Release the antenna lead in cable wire locators. 4 Push the antenna lead in cable into the engine compartment. 10. Move the electric antenna motor forward and down to remove. 11. If necessary, to remove a broken section of plastic antenna drive cable, remove the cover and drive mechanism. 12. Locate and remove the broken piece of drive cable. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Motor > Component Information > Service and Repair > Page 8664 NOTE: The antenna motor and antenna cable are installed as an assembly. 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Fixed Antenna Cable Antenna Cable: Service and Repair Fixed Antenna Cable REMOVAL NOTE: The antenna base and the antenna cable are removed as an assembly. 1. Disconnect the battery ground cable. 2. Remove the radio antenna mast. ^ Slide the wind deflector up. ^ Remove the radio antenna mast by turning it counterclockwise. 3. Unsnap the radio antenna base cap. 4. Remove the radio antenna nut. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Fixed Antenna Cable > Page 8670 5. Remove the front fender apron. 1 Remove the screws. 2 Remove the bolts. 6. Remove the lower antenna mounting screw. 7. Remove the RH cowl side trim panel. 8. Remove the audio unit. For additional information, refer to Radio, Stereo, and Compact Disc. 9. Position the antenna lead-in cable into the engine compartment. 1 Open the glove compartment door. 2 Release the tabs and lower the glove compartment to the full open position. 3 Release the antenna lead-in cable locators. 4 Push the antenna lead-in cable into the engine compartment. 10. Remove the antenna base and the antenna lead-in cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Fixed Antenna Cable > Page 8671 INSTALLATION NOTE: The antenna base and the antenna cable are installed as an assembly. 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Fixed Antenna Cable > Page 8672 Antenna Cable: Service and Repair Power Antenna Cable REMOVAL NOTE: The power antenna cable and the antenna mast are removed as an assembly. 1. Unsnap the radio antenna base cap. 2. Remove the radio antenna nut. 3. Remove the antenna mast and cable. ^ Turn the ignition switch to the ACC position. ^ Turn the radio chassis ON/OFF switch to ON. ^ Firmly pull the antenna mast and cable out of the electric antenna motor. INSTALLATION NOTE: The power antenna cable and antenna mast are installed as an assembly. 1. Position the cable so the teeth are facing the front of the vehicle. NOTE: Check the end of the plastic antenna drive cable for a slight taper. If the drive cable is broken, a section of cable may be inside the electric antenna motor. Remove the broken cable. Refer to Antenna-Motor. 2. Insert the antenna. ^ Manually extend the antenna. ^ Insert the cable until resistance is felt. ^ Turn the cable slightly left and right to full engage the cable into the motor gear. 3. Have an assistant turn the ignition switch to ACC and turn the radio chassis ON/OFF switch from ON to OFF. 4. Apply light downward pressure to the antenna as the electric antenna motor starts retracting the cable. 5. Guide the antenna in as the motor winds the cable into the drive unit and retracts the antenna sections. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Fixed Antenna Cable > Page 8673 6. Install the radio antenna nut. 7. Install the radio antenna base cap. 8. Cycle the electric antenna motor several times to ensure the antenna is extending and retracting correctly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Alarm Module: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8678 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8679 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 8682 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 8683 Alarm Module: Diagrams Remote Anti-Theft Personality Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 8684 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 8685 Alarm Module: Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 8686 Alarm Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 8687 Alarm Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Service Precautions Alarm System Transponder: Service Precautions CAUTION: Once the new module is installed, it is necessary to configure the module. For additional information, refer to Module Communication Network (Information Bus). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Service and Repair > Module-Passive Anti-Theft System (PATS) Alarm System Transponder: Service and Repair Module-Passive Anti-Theft System (PATS) REMOVAL 1. Remove the passenger side air bag module; refer to Air Bags. 2. Remove the passive anti-theft system (PATS) module and bracket. 1 Remove the bolts. 2 Disconnect the electrical connector. 3. Release the retainer tabs and remove the PATS module from the bracket. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Service and Repair > Module-Passive Anti-Theft System (PATS) > Page 8693 1. To install, reverse the removal procedure. CAUTION: Once the new module is installed, it is necessary to configure the module. For additional information, refer to Module Communication Network (Information Bus). NOTE: ^ Prior to starting the vehicle, check for PATS DTCs. Perform the appropriate pinpoint test. ^ When the PATS module is replaced, both ignition keys must be relearned and stored in memory. Insert each key in the ignition and turn to RUN for automatic programming. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Service and Repair > Module-Passive Anti-Theft System (PATS) > Page 8694 Alarm System Transponder: Service and Repair Module-Passive Anti-Theft Transceiver REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the upper and lower steering column shrouds. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Service and Repair > Module-Passive Anti-Theft System (PATS) > Page 8695 5. Remove the hood latch release handle. 1 Remove the screws. 2 Remove the hood latch release handle. 6. Remove the lower instrument panel steering column cover. 1 Remove the screws. 2 Remove the lower instrument panel steering column cover. 7. Remove the instrument panel steering column opening cover reinforcement. 1 Remove the screws. 2 Remove the instrument panel steering column opening cover reinforcement. 8. Remove the transceiver assembly. 1 Remove the screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Service and Repair > Module-Passive Anti-Theft System (PATS) > Page 8696 2 Locate the rib on the steering column lock cylinder housing, and gently release the anti-theft transceiver over the rib. NOTE: Only apply pressure or leverage below the key cylinder lower rib. 3 Disconnect the electrical connector. NOTE: The steering wheel is shown removed for clarity. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 ml) or more to relearn the strategy. ^ No key replacement or re-initialization needs to occur with the removal or installation of a new PATS Transceiver. ^ The steering wheel is shown removed for clarity. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Arm/Disarm Switch, Antitheft > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock Cylinder Arm/Disarm Switch: Service and Repair Switch -Door Disarm, Front Door Lock Cylinder REMOVAL 1. Remove the driver door trim panel. 3. Remove the door disarm switch. 1 Remove the "E" clip. 2 Remove the lock rod actuator. 3 Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: The door disarm switch locator mark must be positioned towards the harness side of the switch prior to installation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Arm/Disarm Switch, Antitheft > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock Cylinder > Page 8701 Arm/Disarm Switch: Service and Repair Switch-Door Disarm, Liftgate Lock Cylinder REMOVAL 1. Remove the liftgate trim panel. 2. Remove the watershield. 3. Remove the liftgate lock cylinder disarm switch. 1 Remove the "E" clip. 2 Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ The liftgate lock cylinder disarm switch locator mark must be positioned towards the harness side of the switch prior to installation. ^ Depress the liftgate lock cylinder to install the liftgate lock cylinder disarm switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Ignition Key In Signal, Antitheft > Component Information > Service and Repair Ignition Key In Signal: Service and Repair Key-In-Ignition Warning Switch REMOVAL 1. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Insert a punch in the access hole of the steering column and press the release tab while pulling out the ignition switch lock cylinder. 2. Remove the key-in-ignition warning switch. 1 Pry the clip down. 2 Push the key-in-ignition warning switch off the rear of the ignition switch lock cylinder. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Ignition Key In Signal, Antitheft > Component Information > Service and Repair > Page 8705 1. To install, reverse the removal procedure. ^ Verify ignition switch lock cylinder operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics Keyless Entry Key-Pad: Technical Service Bulletins Keyless Entry - Keypad Diagnostics TSB 06-15-8 08/07/06 KEYPAD DIAGNOSTICS - DEALER INSTALLED ACCESSORY FORD: 1998-2006 Taurus 1999-2003 Escort 1999-2006 Mustang 2000-2006 Focus 2002-2005 Thunderbird 2005-2006 Five Hundred, Freestyle 2006 Crown Victoria, Fusion 1998-2006 Expedition, Explorer, F-150, Ranger 1999 F-250 Light Duty 1999-2003 Windstar 1999-2006 F-Super Duty 2000-2005 Excursion 2000-2006 E-Series 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004 F-150 Heritage 2004-2006 Freestar LINCOLN: 1998-2006 Town Car 2000-2006 Lincoln LS 2006 Zephyr 1998-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 1998-2005 Sable 1999-2002 Cougar 2005-2006 Montego 2006 Grand Marquis, Milan 1998-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner ISSUE Some vehicles may experience a concern with the keyless entry keypad. In order to properly diagnose the concern with the keyless entry keypad, it is important to identify whether the keypad is a factory installed style (wired) or a Genuine Ford Accessory (GFA) radio frequency (RF) style keypad. ACTION Use the following Service Procedure to identify GFA RF keypads and provide diagnostic service tips. SERVICE PROCEDURE IDENTIFICATION: 1. Production installed keyless entry keypads are mounted flush with the surface of the vehicle and are wired directly to the module controlling the vehicle's keyless entry system. This style keypad can be diagnosed using the appropriate Workshop Manual (WSM), Section 501-14. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 8711 2. Dealer installed GFA RF keypads are adhesive backed and protrude approximately 1/2" (13 mm) from the surface of the vehicle and there are no specific diagnostics available in the WSM (Figure 1). NOTE THIS RF KEYPAD WAS ALSO US[D IN PRODUCTION ON 2004 F-SUPER DUTY VEHICLES BUILT PRIOR TO 12/3/2003. REFER TO WSM, SECTION 501-14 FOR RF KEYPAD DIAGNOSTICS FOR THESE VEHICLES. GENUINE FORD ACCESSORY KEYPAD DIAGNOSTIC TIPS 1. The keypad operates similarly to a remote keyless entry (RKE) transmitter and is programmed using a similar procedure. Although the RF keypad is not specifically addressed in the WSM, the RKE transmitter programming portion of the WSM, Section 501-14 can be used as a guide NOTE THE 7-8 AND 9-0 BUTTONS ON THE KEYPAD MUST BE PRESSED SIMULTANEOUSLY DURING THE PROCEDURE IN ORDER FOR THE KEYPAD TO BE RECOGNIZED AS AN ADDITIONAL REMOTE TRANSMITTER. Since the GFA RF keypad is essentially another RKE transmitter, the transmitter diagnostic pinpoint tests in the vehicle's WSM can also be referenced even though the buttons serving the lock / unlock functions will differ 2. The GFA RF keypad is serviced as an assembly. The internal battery cannot be replaced separately. 3. If the master code or owner selectable code is lost or forgotten, the GFA RF keypad must be replaced. These codes are not stored in any vehicle module (with the exception of 2004 F-Super Duty vehicles produced prior to 12/3/2003). 4. The GFA RF keypad and all RKE transmitters (the number of transmitters allowable will vary by vehicle) must be reprogrammed together anytime the keypad is replaced, an RKE transmitter is replaced, or the module controlling the keyless entry system on the vehicle (GEM/SJB/VSM/DDM etc.) is replaced. NOTE THERE IS AN EXCEPTION TO TIP 4 FOR VEHICLES EQUIPPED WITH INTEGRATED KEYHEAD TRANSMITTERS (IKTs) (FUSION/MILAN/ZEPHYR). THE GFA RF KEYPADS FOR VEHICLES WITH IKTs MUST BE PROGRAMMED INDEPENDENTLY FROM THE IKTs. TURN THE IGNITION FROM "OFF" TO "RUN" 8 TIMES WITHIN 10 SECONDS, WITH THE 8TH TIME ENDING IN "RUN". THE DOOR LOCKS WILL CYCLE TO CONFIRM ENTERING PROGRAMMING MODE. PRESS THE 7-8 AND 9-0 BUTTON ON THE KEYPAD SIMULTANEOUSLY TO SEND A LOCK SIGNAL. TURN IGNITION TO OFF. THE LOCKS WILL CYCLE AGAIN TO INDICATE THE END OF THE PROGRAMMING MODE. 5. The keypad will normally illuminate for 5 seconds after one or more buttons are pressed, and the illumination will immediately turn off if the 7-8 and 9-0 buttons are pressed simultaneously (lock all doors). The keypad contains an optical sensor and will not illuminate under bright lighting conditions. The keypad may only illuminate briefly in colder temperatures in order to maximize the battery power available to transmit a lock/unlock signal. The temperature at which this occurs will vary depending upon the keypad battery age and condition. Both of these conditions are a normal function of the Power Save Mode and do not indicate a need to replace the keypad. 6. After entering the keypad code, the system may unlock the driver's door, lock it, then unlock it again, and the keypad will not even briefly illuminate. This is the Alert Mode and is an indication that battery power is very low and the keypad must be replaced. 7. The keypad also contains an Anti-scan feature. If the wrong code has been entered 7 times (35 consecutive button presses) the keypad is disabled for one minute and the keypad lamp will flash during this time. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 8712 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14A626 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 8713 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 8714 Keyless Entry Key-Pad: Service Precautions CAUTION: Do not operate the radio chassis with a radio speaker disconnected. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 8715 Keyless Entry Key-Pad: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front door trim panel. CAUTION: Do not operate the radio chassis with a radio speaker disconnected. 3. Remove the screws and lift the radio speaker out to gain access to the electrical connector. 4. Disconnect the speaker wiring connector. 5. Disconnect the electrical connector. - Release harness pin-type retainers. 6. Remove the keyless entry keypad and harness. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 8716 1 Remove the clip. 2 Remove the keyless entry keypad and harness. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 10 miles (16 km) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions Keyless Entry Module: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8722 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8723 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8724 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8725 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8726 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8727 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8728 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8729 Keyless Entry Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8730 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8731 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8732 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8733 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8734 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8735 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Page 8736 Keyless Entry Module: Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Page 8737 Keyless Entry Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Page 8738 Keyless Entry Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock Cylinder Lock Cylinder Switch: Service and Repair Switch -Door Disarm, Front Door Lock Cylinder REMOVAL 1. Remove the driver door trim panel. 3. Remove the door disarm switch. 1 Remove the "E" clip. 2 Remove the lock rod actuator. 3 Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: The door disarm switch locator mark must be positioned towards the harness side of the switch prior to installation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock Cylinder > Page 8743 Lock Cylinder Switch: Service and Repair Switch-Door Disarm, Liftgate Lock Cylinder REMOVAL 1. Remove the liftgate trim panel. 2. Remove the watershield. 3. Remove the liftgate lock cylinder disarm switch. 1 Remove the "E" clip. 2 Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ The liftgate lock cylinder disarm switch locator mark must be positioned towards the harness side of the switch prior to installation. ^ Depress the liftgate lock cylinder to install the liftgate lock cylinder disarm switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Locations > Page 8747 Security Lamp/Indicator: Description and Operation Once triggered, the anti-theft system flashes the low beam headlamps, the parking lamps, the THEFT indicator and sounds the horns. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations Parking Assist Control Module: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 8752 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 8753 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 8754 Parking Assist Control Module: Service and Repair REMOVAL 1. Remove the jack storage panel. 2. Remove the parking aid module. 1 Disconnect the electrical connector. 2 Remove the screws. 3 Remove the parking aid module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings Parking Assist Distance Sensor: Customer Interest Parking Assist System - False Warnings TSB 05-4-18 03/07/05 FALSE PARKING AID WARNINGS FORD: 1999-2001 Explorer, Windstar 2000-2001 Excursion, Expedition 2001 F-Super Duty LINCOLN: 2000-2001 Navigator MERCURY: 1999-2001 Mountaineer This article supersedes TSB 04-26-2 to update the vehicle lines and model years. ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This condition may also occur on vehicles equipped with the forward sensing system (FSS) when vehicle is in reverse or drive. ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before replacing any sensor(s). SERVICE TIPS NOTE THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS. OPERATION AND COMMON CAUSE OF WARNINGS The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the FSS the system is operational when the vehicle is in reverse or drive. The FSS and RSS give an audible warning to the driver when obstacles are within 6' (1.8 meters) from the vehicle, and when obstacles are within 18" (46 cm) on either side of the bumper. NOTE CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS COMPOSED OF. NOTE THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE EXCEPTION STATED IN THE NOTE ABOVE. NOTE THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT ADJUSTABLE. In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or give warnings for 3 seconds then ceases, the occurrence may be due to any of the following reasons: BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE: Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 8763 Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is contaminated with any foreign material the system may sound a continuous tone or intermittent tone. The sensor surface can be cleaned by a high pressure water spray. SIDE COVERAGE SENSOR: There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large, extending obstacle such as a garage wall. If there is no encroachment between any of the outer sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the obstacle begin to move closer to each other, then the warning will begin again. Obstacles within 10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal operation. ABNORMAL ROAD SURFACES: The RSS/FSS may give warnings due to certain road surfaces with surface projections such as rocks, broken pavement, unplowed snow covered roads. This is considered normal operation. OTHER POSSIBLE CAUSES: Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External ultrasonic noise may be detected (high velocity air, machinery). This is considered normal operation. SENSOR DIAGNOSTICS 1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and within 6' (1.8 meters) of the front of the vehicle for the FSS. 2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high pressure water wash to ensure that the membrane gap is free of any dirt or contamination. 3. Using the New Generation Star (NGS) tester or WDS, observe the following four (4) parking aid module parameter identification displays (PIDs) for distance information: ^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle) ^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle) ^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle) ^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle) NOTE PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED. a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches (NGS+ and WDS). b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation procedures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 8764 ACCESSING PIDS WITH NGS, SELECT: ^ Vehicle Line ^ Diagnostic Data Link ^ PAM ^ PID/Data Monitor And Record ^ Select the appropriate PIDS ^ Start ACCESSING PIDS WITH WDS, START VEHICLE SESSION THEN SELECT: ^ Toolbox Icon ^ Datalogger, Then Tick (Check Mark) ^ Modules, Then Tick ^ PAM, Then Tick ^ Select The Appropriate PIDS, Then Tick WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 15K859 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings Parking Assist Distance Sensor: All Technical Service Bulletins Parking Assist System - False Warnings TSB 05-4-18 03/07/05 FALSE PARKING AID WARNINGS FORD: 1999-2001 Explorer, Windstar 2000-2001 Excursion, Expedition 2001 F-Super Duty LINCOLN: 2000-2001 Navigator MERCURY: 1999-2001 Mountaineer This article supersedes TSB 04-26-2 to update the vehicle lines and model years. ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This condition may also occur on vehicles equipped with the forward sensing system (FSS) when vehicle is in reverse or drive. ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before replacing any sensor(s). SERVICE TIPS NOTE THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS. OPERATION AND COMMON CAUSE OF WARNINGS The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the FSS the system is operational when the vehicle is in reverse or drive. The FSS and RSS give an audible warning to the driver when obstacles are within 6' (1.8 meters) from the vehicle, and when obstacles are within 18" (46 cm) on either side of the bumper. NOTE CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS COMPOSED OF. NOTE THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE EXCEPTION STATED IN THE NOTE ABOVE. NOTE THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT ADJUSTABLE. In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or give warnings for 3 seconds then ceases, the occurrence may be due to any of the following reasons: BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE: Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 8770 Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is contaminated with any foreign material the system may sound a continuous tone or intermittent tone. The sensor surface can be cleaned by a high pressure water spray. SIDE COVERAGE SENSOR: There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large, extending obstacle such as a garage wall. If there is no encroachment between any of the outer sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the obstacle begin to move closer to each other, then the warning will begin again. Obstacles within 10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal operation. ABNORMAL ROAD SURFACES: The RSS/FSS may give warnings due to certain road surfaces with surface projections such as rocks, broken pavement, unplowed snow covered roads. This is considered normal operation. OTHER POSSIBLE CAUSES: Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External ultrasonic noise may be detected (high velocity air, machinery). This is considered normal operation. SENSOR DIAGNOSTICS 1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and within 6' (1.8 meters) of the front of the vehicle for the FSS. 2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high pressure water wash to ensure that the membrane gap is free of any dirt or contamination. 3. Using the New Generation Star (NGS) tester or WDS, observe the following four (4) parking aid module parameter identification displays (PIDs) for distance information: ^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle) ^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle) ^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle) ^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle) NOTE PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED. a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches (NGS+ and WDS). b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation procedures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 8771 ACCESSING PIDS WITH NGS, SELECT: ^ Vehicle Line ^ Diagnostic Data Link ^ PAM ^ PID/Data Monitor And Record ^ Select the appropriate PIDS ^ Start ACCESSING PIDS WITH WDS, START VEHICLE SESSION THEN SELECT: ^ Toolbox Icon ^ Datalogger, Then Tick (Check Mark) ^ Modules, Then Tick ^ PAM, Then Tick ^ Select The Appropriate PIDS, Then Tick WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 15K859 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 8772 Parking Assist Distance Sensor: Specifications Azimuth System Check Object Position 1 (P1) and Position 5 (P5), Distance From Sensor 90 cm Azimuth System Check Object Position 2 (P2), 3 (P3) and Position 4 (P4), Distance From Sensor 160 cm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 8773 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 8774 Parking Assist Distance Sensor: Service and Repair REMOVAL 1. Remove the rear bumper. 2. Remove the parking aid sensor. 1 Disconnect the electrical connector. 2 Release the tabs. 3 Remove the parking aid sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Switch > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Switch > Component Information > Diagrams > Page 8778 Parking Assist Switch: Service and Repair REMOVAL 1. Remove the audio unit. For additional information, refer to Radio, Stereo, and Compact Disc. 2. Remove the center instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connector. 3. Remove the hood latch release handle. 1 Remove the screws. 2 Remove the hood latch release handle. 4. Remove the instrument panel lower steering column cover. 1 Remove the screws. 2 Remove the instrument panel lower steering column cover. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Switch > Component Information > Diagrams > Page 8779 5. Remove the instrument panel steering column opening cover reinforcement. 1 Remove the screws. 2 Remove the instrument panel steering column opening cover reinforcement. 6. If equipped, position the column gearshift lever aside. 7. Remove the instrument cluster finish panel. 1 Remove the screws. 2 Remove the instrument cluster finish panel. ^ Disconnect the electrical connector. 8. Remove the parking aid switch. 1 Remove the screws. 2 Remove the parking aid switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Warning Indicator > Component Information > Service and Repair Parking Assist Warning Indicator: Service and Repair REMOVAL 1. Remove the LH quarter trim panel. 2. Remove the parking aid speaker. 1 Disconnect the electrical connector. 2 Remove the pin-type retainers. 3 Remove the parking aid speaker. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8787 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8788 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8789 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8790 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8791 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8792 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8793 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8794 Driver/Vehicle Information Display: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8795 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8796 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8797 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8798 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8799 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8800 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8801 Driver/Vehicle Information Display: Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8802 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8803 Driver/Vehicle Information Display: Electrical Diagrams Diagram 69-1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8804 Diagram 69-2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > System Description Driver/Vehicle Information Display: Description and Operation System Description The message center system consists of: - message center switch module - message center indicator Message Center Switch Module The message center switch module has seven switches and is located below the message center indicator in the center console. The message center switches are: ENGLISH/METRIC mode - fuel computer (FUEL) RANGE - STATUS - economy (ECON) - RESET - system check and warnings (SYSTEM CHECK) - OIL CHANGE RESET Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > System Description > Page 8807 Driver/Vehicle Information Display: Description and Operation Principles of Operation (How Does It Work ?) Display Dimming The dimming of the indicator display is controlled by the pulse width dimmer module. The voltage on Pin 2 controls the brightness of the message center display. When the exterior lamps are off, this voltage will be zero volts and the message center display will be at maximum brightness. When the exterior lamps are on, this voltage will be controlled by the pulse width dimmer module and will be between 2.5 volts and battery voltage. The message center display will be brighter as this voltage approaches battery voltage. If there is a warning on the message center display, the display will not dim to its lowest level. When the headlamps or parking lamps are OFF, the display of the message center indicator will be maximum brightness and the labels for the center five switches of the message center switch module will not be illuminated. When the head lamps or parking lamps are ON, the brightness of the display of the message center indicator and the labels for the center five switches of the message center switch module will be controlled by the pulse width dimmer module. English/Metric Mode The ENGLISH/METRIC switch controls the display mode for both the message center indicator and the electronic automatic temperature control. A press of the ENGLISH/METRIC switch will change both displays between english mode and metric mode. Vehicle Speed Signal The vehicle speed signal is generated by the rear anti-lock brake sensor and sent to the 4-wheel Anti-lock Brake System (4WABS) module. The 4WABS module sends the vehicle speed signal via circuit 679 (GY/BK) to all systems which require a vehicle speed signal input. Fuel Computer - Range The RANGE feature has two displays: the distance that can be traveled before refueling, and the distance that was traveled since the last trip odometer reset. The RANGE switch will change the message center indicator between the two displays. The RANGE (distance to empty) feature is calculated using the fuel flow signal from the Powertrain Control Module (PCM), the speed signal from the 4WABS module and the fuel level signal from the fuel level sender. The fuel flow and speed signals are used to calculate a Running Average Fuel Economy (RAFE), which is multiplied by the fuel remaining to give the range. RAFE is not the same number as the Average Fuel Economy displayed by the message center indicator. RAFE is based on the past driving history and can only be reset by disconnecting the battery. When the range decreases to 80 km (50 mile) to empty, the message center will display the LOW FUEL LEVEL warning. With a fuel tank full of fuel (160 ohm signal from fuel sender) and after a battery disconnect, the RANGE should be approximately 644 km (400 miles) to empty. The RANGE (trip odometer) feature is calculated using the speed signal from the 4WABS module. It can be reset to zero by pressing the reset switch while the trip odometer is displayed on the message center. Fuel Computer - Status The STATUS feature has two displays: Fuel-to-Empty and Fuel-Used. The STATUS switch will change the message center indicator between the two displays. The fuel-to-empty calculation is achieved using the fuel level signal from the fuel level sender. The fuel-used feature is calculated using the fuel flow signal from the PCM and can be reset to zero by pressing the RESET switch while the fuel-used feature is displayed on the message center. Fuel Computer - Economy The Economy (ECON) feature has two displays: average and instant. Depressing the ECON switch changes the message center indicator between both displays. The economy is calculated using the fuel flow signal from the powertrain control module and the speed signal from the 4WABS module. The average fuel economy feature can be reset by pressing the RESET switch while the average fuel economy feature is displayed on the message center indicator. System Check and Warnings Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > System Description > Page 8808 The SYSTEM CHECK feature cycles the message center indicator through a status of each system being monitored. For each of the monitored systems, the message center indicator will indicate either an OK message or a warning message for two seconds. - At normal conclusion of the system check sequence, the message center indicator will display all active warnings or the last feature displayed before entering the SYSTEM CHECK mode. - System warnings alert the driver to possible concerns or malfunctions in the vehicle operating systems. - There are 7 warning messages which can be displayed for two seconds by the message center indicator to show the status of the monitored systems. - When a warning occurs, the warning message is displayed and a one-second tone sounds. The warning message will appear at a brighter level if the message center indicator is dimmed. - In the event of a multiple warning situation, the message center indicator will cycle the display to show all warnings by displaying each warning message for four seconds. - To display the operator selectable features of the message center indicator while a warning is displayed, the warning message may be removed from the message center indicator display by pressing the RESET switch. The message center indicator will display the last selected feature if there are no more warning messages. - This allows operation of all functions of the message center indicator after pressing the RESET switch and clearing the warning message. Warning messages which have been reset will either reappear on the display in 10 minutes from the reset or will not reappear until an ignition switch OFF-RUN cycle. If warning messages reappear it is a reminder that these warning conditions still exist. Warnings may be repeatedly reset. All warning messages will reappear after an entire SYSTEM CHECK sequence has been completed. Charging System Warning (CHECK CHARGING SYSTEM) This warning message is displayed when the electrical system is not maintaining correct voltage at the message center indicator. There will be a few seconds delay before the warning is displayed or removed. Engine Coolant Temperature Warning (CHECK ENGINE TEMP) This warning message is displayed when the engine coolant is overheating. The message center indicator senses the voltage level on Circuit 39 (RD/WH) (to the message center indicator). If that voltage is greater than approximately 2.7 volts, at a battery voltage of 13.5 volts there will be no warning. If it is less than approximately 2.7 volts, at a battery voltage of 13.5 volts then the warning will be displayed. The message center indicator filters this input; therefore, there will be a few seconds delay before the warning is displayed or removed. Fuel Level Warning (LOW FUEL LEVEL) This warning message is displayed when there is approximately 80 km (50 mile) or less left before the vehicle runs out of fuel. Oil Level Warning (LOW OIL LEVEL) This warning message is displayed when the engine oil level is low. When the engine oil level is normal, the input to the message center indicator will be an open circuit. When the engine oil level is low, the low oil level sensor will close, grounding the input to the message center indicator and the warning will be displayed during the next ignition cycle of OFF to RUN. This low oil level sensor is only monitored when the ignition switch is OFF. There is a delay of up to 12 minutes in this monitoring in order to allow the oil to drain back into the oil pan and reach the correct level. Oil Life Warning (CHANGE OIL SOON or OIL CHANGE REQUIRED) If the connection to the oil temperature sensor is open circuit or shorted, the message center display will read OIL TEMP SIGNAL ERROR instead of displaying the PERCENTAGE OIL LIFE LEFT during system cheek sequence. One of these warning messages is displayed when the engine oil life remaining is five percent or less. When oil life left is between five percent and zero percent, the "CHANGE OIL SOON" message will be displayed. - When oil life left reaches zero percent, the "OIL CHANGE REQUIRED" message will be displayed. The message center indicator will indicate the percent of oil life remaining during System Check. This percentage is based on the driving history and the time since the last oil change. In order to ensure accurate oil life left indications, the driver should only carry out the OIL CHANGE RESET procedure, as described in the Owner's Guide, after an oil change. To calculate the percentage of oil life remaining, the oil life feature uses: oil temperature sensor input - tachometer input from the PCM - vehicle speed signal input - clock time (maintained internally by the message center) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > System Description > Page 8809 - The oil life will decrease from 100 percent to 0 percent in no more than 12,070 km (7,500 mile) or 6 months. It will reach zero percent sooner under different driving conditions. - The percentage of oil life remaining is the second display in the system check sequence. - When oil life remaining is between five percent and zero percent, the "CHANGE OIL SOON" message will be displayed. - When oil life left reaches zero percent, the "OIL CHANGE REQUIRED" message will be displayed. Washer Fluid Level Warning (LOW WASHER FLUID) This warning message is displayed when there is less than one quarter of the container of washer fluid remaining When the washer fluid level is normal, the windshield washer reservoir fluid level sensor will close, grounding the input Circuit 82 (PK/YE) at C200931 of the message center indicator. - When the washer fluid level is low, the input to the message center indicator will be open and the warning will be displayed. The message center indicator filters this input therefore, there will be a 20-second delay before the warning is displayed or removed. Warning Chime A short warning chime (0.1 second) is output with every message center switch press. A longer warning chime (1.0 second) is output when a new warning first appears on the message center indicator display. To activate the warning, the message center pulls the chime request output below one volt during the length of the tone. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Page 8810 Driver/Vehicle Information Display: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is part of, please refer to Instrument Panel, Gauges and Warning indicators; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Message Center Assembly Driver/Vehicle Information Display: Service and Repair Message Center Assembly REMOVAL 1. Remove the message center console. Grasp the front of the console and lift upward. 2. Disconnect the electrical connectors from the message center indicator. 3. Remove the screws retaining the message center indicator. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Message Center Assembly > Page 8813 Driver/Vehicle Information Display: Service and Repair Message Center Assembly Switch REMOVAL 1. Remove the message center indicator. Refer to Driver/Vehicle Information Display. 2. Disconnect the electrical connector. 3. Remove the message center switch module screws and remove the module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Page 8814 73 Digital Multimeter Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Locations > Page 8818 Garage Door Opener Transmitter: Service Precautions WARNING: A GARAGE DOOR OPENING SYSTEM THAT CANNOT STOP OR REVERSE ITSELF AFTER DETECTING AN OBJECT IN ITS PATH DOES NOT MEET CURRENT FEDERAL SAFETY STANDARDS. TO DECREASE THE RISK OF SERIOUS INJURY OR DEATH, DO NOT USE THIS HOMELINK(R) WITH TRAVELNOTE TM TRANSMITTER WITH A DOOR OPENING SYSTEM THAT LACKS STOP AND REVERSE FEATURES AS REQUIRED BY FEDERAL STANDARDS. THIS INCLUDES ANY GARAGE DOOR OPENING SYSTEM MANUFACTURED BEFORE APRIL 1, 1982. FOR MORE INFORMATION, CALL HOMELINK(R) WITH TRAVELNOTE TM CUSTOMER ASSISTANCE AT 1-800-355-3515. CAUTION: During this procedure, the system that you are programming will be made to operate. Make sure that people or objects are clear of the garage door or gate being programmed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Locations > Page 8819 Garage Door Opener Transmitter: Description and Operation The HomeLink(R) with TravelNote TM universal transmitter provides a convenient way to replace up to three hand-held transmitters with a single built-in device. The universal transmitter: ^ will operate garage doors, gates and home/office lighting and security systems. ^ will actually learn and transmit the radio frequency of up to three hand-held transmitters from any of the systems mentioned above. ^ is an integral part of the left sun visor assembly and is powered by the vehicle battery and charging system. In addition to the universal transmitter function, the HomeLink(R) with TravelNote TM also provides a convenient built-in recording device to safely store information. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Garage Door Opener Transmitter: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged universal transmitter ^ Damaged receiver 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the fault is not visually evident, verify the symptom and refer to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8822 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8823 Garage Door Opener Transmitter: Pinpoint Tests Connector Circuit Reference Refer to the Vehicle/Diagrams for schematic and connector information. A1 - A2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Page 8824 Garage Door Opener Transmitter: Service and Repair WARNING: A GARAGE DOOR OPENING SYSTEM THAT CANNOT STOP OR REVERSE ITSELF AFTER DETECTING AN OBJECT IN ITS PATH DOES NOT MEET CURRENT FEDERAL SAFETY STANDARDS. TO DECREASE THE RISK OF SERIOUS INJURY OR DEATH, DO NOT USE THIS HOMELINK(R) WITH TRAVELNOTE TM TRANSMITTER WITH A DOOR OPENING SYSTEM THAT LACKS STOP AND REVERSE FEATURES AS REQUIRED BY FEDERAL STANDARDS. THIS INCLUDES ANY GARAGE DOOR OPENING SYSTEM MANUFACTURED BEFORE APRIL 1, 1982. FOR MORE INFORMATION, CALL HOMELINK(R) WITH TRAVELNOTE TM CUSTOMER ASSISTANCE AT 1-800-355-3515. 1. Verify the hand-held transmitter is operative. CAUTION: During this procedure, the system that you are programming will be made to operate. Make sure that people or objects are clear of the garage door or gate being programmed. 2. Prepare for programming the universal transmitter by erasing all three channels by holding down the two outside buttons until the red light begins to flash (20 - 30 seconds). Release both buttons. 3. Select one of the three universal transmitter channels to be programmed by pressing the desired button. 4. Hold the end of the hand-held transmitter 25 - 51 mm (1 - 2 in) from the front surface of the universal transmitter so that the red light can still be seen. 5. Use both hands to press the hand-held transmitter button and the desired button on the universal transmitter. Do not release either button. NOTE: During programming, the hand-held transmitter may automatically stop transmitting after two seconds, which may not be long enough to program the universal transmitter. If programming this type of hand-held transmitter, continue to hold the button on the universal transmitter while re-pressing the hand-held transmitter button every two seconds (Canada only). 6. Hold down both buttons until the red light on the universal transmitter flashes, first slowly and then rapidly. Release both buttons when the rapid flashing begins. The universal transmitter has successfully learned the new frequency signal and can be used in place of the hand-held transmitter(s). 7. To operate, simply press the appropriate button on the universal transmitter. The red light is on while the signal is being transmitted. NOTE: If the hand-held transmitter appears to program the universal transmitter but does not open the garage door, the garage door opener may have a "code protected" or "rolling code" feature. Training a Garage Door Opener Equipped With "Rolling Codes" 1. Program the hand-held transmitter to the universal transmitter. 2. Train the garage door opener receiver to recognize the universal transmitter. 1 Remove the cover panel from the garage door opener receiver. 2 Locate the training button on the garage door opener receiver. Location and color of the button may vary by garage door opener manufacturer. Refer to the garage door opener instruction manual or call HomeLink(R) with TravelNote TM customer assistance at 1-800-355-3515. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Page 8825 3 Press the training button on the garage door opener receiver for 1 - 2 seconds. 4 Press the programmed universal transmitter button for as long as the universal transmitter red light flashes (1 - 2 seconds). Release the button and re-press the button to confirm that the universal transmitter is trained to the receiver. 5 The garage door opener should recognize the universal transmitter. Erasing Channels 1. To erase all three programmed channels, hold down the two outside buttons until the red light begins to flash (20 - 30 seconds). Release both buttons. NOTE: Individual channels cannot be erased, but can be reprogrammed using the procedures for programming. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Specifications Multifunction Electronic Control Modules: Specifications Remote Anti-Theft Personality Module 2.3-3.3 Nm Battery Ground Cable Screws 7-10 Nm GEM/CTM Screw 1.6-2.0 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Specifications > Page 8829 Multifunction Electronic Control Modules: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Specifications > Page 8830 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions Multifunction Electronic Control Modules: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8833 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8834 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8835 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8836 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8837 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8838 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8839 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8840 Multifunction Electronic Control Modules: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8841 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8842 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8843 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8844 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8845 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8846 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8847 Multifunction Electronic Control Modules: Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8848 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8849 Multifunction Electronic Control Modules: Electrical Diagrams Diagram 59-1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8850 Diagram 59-2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8851 Diagram 59-3 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8852 Diagram 59-4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8853 Diagram 59-5 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8854 Diagram 59-6 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 8855 Multifunction Electronic Control Modules: Description and Operation The multifunction modules consist of the following: ^ generic electronic module (GEM)/central timer module (CTM) ^ remote anti-theft personality (RAP) module The remote anti-theft personality (RAP) module controls the keyless entry, and computer operated locks systems. The GEM/CTM controls the following features: ^ wiper/washer (front/rear) ^ warning chime ^ battery saver ^ illuminated entry and courtesy lamps ^ driver one touch down power window (GEM only) ^ accessory delay ^ 4 wheel drive (GEM only) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 8856 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Module - Generic Electronic (GEM)/Central Timer (CTM) Multifunction Electronic Control Modules: Service and Repair Module - Generic Electronic (GEM)/Central Timer (CTM) REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 2. Remove the radio chassis; refer to Radio, Stereo, and Compact Disc. 3. Remove the center instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 4. Remove the GEM/CTM. 1 Remove the screw. 2 Disconnect the four connectors from the GEM/CTM. 3 Remove the GEM/CTM. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Module - Generic Electronic (GEM)/Central Timer (CTM) > Page 8859 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Module - Generic Electronic (GEM)/Central Timer (CTM) > Page 8860 Multifunction Electronic Control Modules: Service and Repair Module - Remote Anti-Theft Personality (RAP) REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these static charges, damage may result. 2. Remove the LH rear quarter trim panel. 3. Disconnect the two remote anti-theft personality (RAP) module electrical connectors. 4. Remove the two RAP module fasteners. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Module - Generic Electronic (GEM)/Central Timer (CTM) > Page 8861 5. Remove the RAP module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Specifications Amplifier: Specifications Radio Amplifier Bracket Bolt 10-14 Nm Radio Amplifier Bracket Nut 7-9 Nm Radio Amplifier Bracket Screw 7-10 Nm Radio Amplifier Mounting Screw 7-10 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Specifications > Page 8874 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Page 8879 CD Changer: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the console compartment trim panel. ^ Remove the screws. ^ Remove the console compartment trim panel. 3. Remove the coin holder/tissue box holder. 4. Position the CD changer aside. 1 Remove the screws. 2 Position aside the CD changer. 5. Remove the CD changer. 1 Disconnect the connector. 2 Remove the screws. 3 Remove the CD changer brackets. 4 Remove the CD changer. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Page 8880 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 SOHC VIN K SFI (2001)) 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 8890 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 SOHC VIN K SFI (2001)) 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 8891 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 SOHC VIN K SFI (2001)) 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 8892 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 SOHC VIN K SFI (2001)) 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 8893 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 SOHC VIN K SFI (2001)) 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 8894 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 SOHC VIN K SFI (2001)) 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 8895 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 8896 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 SOHC VIN K SFI (2001)) 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 8902 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 SOHC VIN K SFI (2001)) 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 8903 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 SOHC VIN K SFI (2001)) 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 8904 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 SOHC VIN K SFI (2001)) 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 8905 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 SOHC VIN K SFI (2001)) 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 8906 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 SOHC VIN K SFI (2001)) 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 8907 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 8908 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Page 8909 Radio/Stereo Noise Filter: Specifications Intake Manifold Ground Strap Nut ...................................................................................................................................................... 7-9 Nm (62-80 Lb-In) Radio Chassis Rear Support Nut ....................................................................................................................................................... 3.5-4 Nm (31-35 Lb-In) Rear Integrated Control Panel Screws .................................................................................................................................................. 2-3 Nm (17-26 Lb-In) Wiper Motor Stud Ground Strap Nut ................................................................................................................................................... 7-9 Nm (62-80 Lb-In) Rear Radio Chassis Support .............................................................................................................................................................. 3.5-4 Nm (31-35 Lb-In) Battery Ground Cable Screw .............................................................................................................................................................. 7-10 Nm (62-89 Lb-In) Cylinder Head Ground Strap Bolt .............................................................................................................................................. 8.9-12.1 Nm (79-107 Lb-In) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Page 8910 Radio/Stereo Noise Filter: Description and Operation Radio Frequency Interference Suppression Equipment The radio suppression equipment reduces interference transmitted through the radio speakers by the engine ignition and electrical systems. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Page 8911 Radio/Stereo Noise Filter: Service and Repair GROUND STRAP REMOVAL 1. Disconnect the battery ground cable. 2. Remove the nut and washer (A) attaching the ground strap (B) to the stud. 3. Remove the fastener from the rear of the right cylinder head and ensure that the mounting surfaces of the studs are free of dirt and corrosion. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Page 8912 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Service and Repair Remote Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the steering wheel controls. 1 Carefully remove the steering wheel controls. 2 Disconnect the steering wheel controls. NOTE: The steering wheel is leather wrapped and should be protected when removing the steering wheel controls. INSTALLATION 1. Install the steering wheel controls. 1 Connect the steering wheel controls. 2 Install the steering wheel controls. 2. Connect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Service and Repair Remote Control: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the console compartment trim panel screws. 3. Remove the console compartment door hinge screw. 4. Remove the console rear panel screws at the top of the panel. 5. Remove the console rear panel screws at the cupholder. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Service and Repair > Page 8919 6. Remove the rear integrated control panel screws. 7. Disconnect the floor/panel control arm at the control head. 8. Disconnect the rear blower motor control and rear radio controls electrical connectors. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Service and Repair > Page 8920 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 8929 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 8930 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 8931 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 8932 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 8933 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 8934 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 8935 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8941 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8942 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8943 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8944 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8945 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8946 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8947 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 8948 Speaker: Specifications Speaker Screws 2 Nm Subwoofer Screws 6.8-9.2 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 8949 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 8950 Speaker: Description and Operation The Explorer and Mountaineer are equipped with four premium radio speakers and an optional subwoofer. Rear radio speakers are mounted in the rear doors in four-door models or in the quarter panel in two-door models. Front radio speakers are mounted in the front doors. The optional MACH sound system replaces the front door premium radio speakers with audiophile radio speakers. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Mounted Speakers Speaker: Service and Repair Door Mounted Speakers REMOVAL 1. Remove the front door trim panels. 2. Remove the speakers. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the speakers. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Mounted Speakers > Page 8953 Speaker: Service and Repair Rear (2 Door) Speaker REMOVAL 1. Remove the quarter trim panel. 2. Remove the speaker. 1 Remove the screws. 2 Disconnect the electrical connector. 3 Remove the speaker. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Door Mounted Speakers > Page 8954 Speaker: Service and Repair Subwoofer Speaker REMOVAL 1. Remove the quarter trim panel. 2. Remove the subwoofer. 1 Disconnect the electrical connector. 2 Remove the screws. 3 Remove the subwoofer. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Accessory Delay Relay: Locations The Generic Electronic Module (GEM) / Central Timer Module (CTM) Controls the Accessory Delay Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8960 Accessory Delay Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Alarm Module: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8964 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 8965 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 8968 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 8969 Alarm Module: Diagrams Remote Anti-Theft Personality Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 8970 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 8971 Alarm Module: Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 8972 Alarm Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 8973 Alarm Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Locations > Page 8977 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Specifications Multifunction Electronic Control Modules: Specifications Remote Anti-Theft Personality Module 2.3-3.3 Nm Battery Ground Cable Screws 7-10 Nm GEM/CTM Screw 1.6-2.0 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Specifications > Page 8981 Multifunction Electronic Control Modules: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Specifications > Page 8982 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions Multifunction Electronic Control Modules: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8985 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8986 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8987 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8988 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8989 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8990 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8991 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8992 Multifunction Electronic Control Modules: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8993 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8994 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8995 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8996 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8997 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8998 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8999 Multifunction Electronic Control Modules: Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9001 Multifunction Electronic Control Modules: Electrical Diagrams Diagram 59-1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9002 Diagram 59-2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9003 Diagram 59-3 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9004 Diagram 59-4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9005 Diagram 59-5 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9006 Diagram 59-6 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 9007 Multifunction Electronic Control Modules: Description and Operation The multifunction modules consist of the following: ^ generic electronic module (GEM)/central timer module (CTM) ^ remote anti-theft personality (RAP) module The remote anti-theft personality (RAP) module controls the keyless entry, and computer operated locks systems. The GEM/CTM controls the following features: ^ wiper/washer (front/rear) ^ warning chime ^ battery saver ^ illuminated entry and courtesy lamps ^ driver one touch down power window (GEM only) ^ accessory delay ^ 4 wheel drive (GEM only) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 9008 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Module - Generic Electronic (GEM)/Central Timer (CTM) Multifunction Electronic Control Modules: Service and Repair Module - Generic Electronic (GEM)/Central Timer (CTM) REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 2. Remove the radio chassis; refer to Radio, Stereo, and Compact Disc. 3. Remove the center instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 4. Remove the GEM/CTM. 1 Remove the screw. 2 Disconnect the four connectors from the GEM/CTM. 3 Remove the GEM/CTM. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Module - Generic Electronic (GEM)/Central Timer (CTM) > Page 9011 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Module - Generic Electronic (GEM)/Central Timer (CTM) > Page 9012 Multifunction Electronic Control Modules: Service and Repair Module - Remote Anti-Theft Personality (RAP) REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these static charges, damage may result. 2. Remove the LH rear quarter trim panel. 3. Disconnect the two remote anti-theft personality (RAP) module electrical connectors. 4. Remove the two RAP module fasteners. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Module - Generic Electronic (GEM)/Central Timer (CTM) > Page 9013 5. Remove the RAP module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions Keyless Entry Module: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9019 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9020 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9021 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9022 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9023 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9024 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9025 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9026 Keyless Entry Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9027 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9028 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9029 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9030 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9031 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9032 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Page 9033 Keyless Entry Module: Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Page 9034 Keyless Entry Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Page 9035 Keyless Entry Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations Parking Assist Control Module: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 9042 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 9043 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 9044 Parking Assist Control Module: Service and Repair REMOVAL 1. Remove the jack storage panel. 2. Remove the parking aid module. 1 Disconnect the electrical connector. 2 Remove the screws. 3 Remove the parking aid module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock Cylinder Arm/Disarm Switch: Service and Repair Switch -Door Disarm, Front Door Lock Cylinder REMOVAL 1. Remove the driver door trim panel. 3. Remove the door disarm switch. 1 Remove the "E" clip. 2 Remove the lock rod actuator. 3 Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: The door disarm switch locator mark must be positioned towards the harness side of the switch prior to installation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock Cylinder > Page 9050 Arm/Disarm Switch: Service and Repair Switch-Door Disarm, Liftgate Lock Cylinder REMOVAL 1. Remove the liftgate trim panel. 2. Remove the watershield. 3. Remove the liftgate lock cylinder disarm switch. 1 Remove the "E" clip. 2 Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ The liftgate lock cylinder disarm switch locator mark must be positioned towards the harness side of the switch prior to installation. ^ Depress the liftgate lock cylinder to install the liftgate lock cylinder disarm switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock Cylinder Lock Cylinder Switch: Service and Repair Switch -Door Disarm, Front Door Lock Cylinder REMOVAL 1. Remove the driver door trim panel. 3. Remove the door disarm switch. 1 Remove the "E" clip. 2 Remove the lock rod actuator. 3 Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: The door disarm switch locator mark must be positioned towards the harness side of the switch prior to installation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock Cylinder > Page 9055 Lock Cylinder Switch: Service and Repair Switch-Door Disarm, Liftgate Lock Cylinder REMOVAL 1. Remove the liftgate trim panel. 2. Remove the watershield. 3. Remove the liftgate lock cylinder disarm switch. 1 Remove the "E" clip. 2 Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: ^ The liftgate lock cylinder disarm switch locator mark must be positioned towards the harness side of the switch prior to installation. ^ Depress the liftgate lock cylinder to install the liftgate lock cylinder disarm switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings Parking Assist Distance Sensor: Customer Interest Parking Assist System - False Warnings TSB 05-4-18 03/07/05 FALSE PARKING AID WARNINGS FORD: 1999-2001 Explorer, Windstar 2000-2001 Excursion, Expedition 2001 F-Super Duty LINCOLN: 2000-2001 Navigator MERCURY: 1999-2001 Mountaineer This article supersedes TSB 04-26-2 to update the vehicle lines and model years. ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This condition may also occur on vehicles equipped with the forward sensing system (FSS) when vehicle is in reverse or drive. ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before replacing any sensor(s). SERVICE TIPS NOTE THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS. OPERATION AND COMMON CAUSE OF WARNINGS The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the FSS the system is operational when the vehicle is in reverse or drive. The FSS and RSS give an audible warning to the driver when obstacles are within 6' (1.8 meters) from the vehicle, and when obstacles are within 18" (46 cm) on either side of the bumper. NOTE CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS COMPOSED OF. NOTE THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE EXCEPTION STATED IN THE NOTE ABOVE. NOTE THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT ADJUSTABLE. In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or give warnings for 3 seconds then ceases, the occurrence may be due to any of the following reasons: BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE: Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 9064 Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is contaminated with any foreign material the system may sound a continuous tone or intermittent tone. The sensor surface can be cleaned by a high pressure water spray. SIDE COVERAGE SENSOR: There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large, extending obstacle such as a garage wall. If there is no encroachment between any of the outer sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the obstacle begin to move closer to each other, then the warning will begin again. Obstacles within 10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal operation. ABNORMAL ROAD SURFACES: The RSS/FSS may give warnings due to certain road surfaces with surface projections such as rocks, broken pavement, unplowed snow covered roads. This is considered normal operation. OTHER POSSIBLE CAUSES: Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External ultrasonic noise may be detected (high velocity air, machinery). This is considered normal operation. SENSOR DIAGNOSTICS 1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and within 6' (1.8 meters) of the front of the vehicle for the FSS. 2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high pressure water wash to ensure that the membrane gap is free of any dirt or contamination. 3. Using the New Generation Star (NGS) tester or WDS, observe the following four (4) parking aid module parameter identification displays (PIDs) for distance information: ^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle) ^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle) ^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle) ^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle) NOTE PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED. a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches (NGS+ and WDS). b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation procedures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 9065 ACCESSING PIDS WITH NGS, SELECT: ^ Vehicle Line ^ Diagnostic Data Link ^ PAM ^ PID/Data Monitor And Record ^ Select the appropriate PIDS ^ Start ACCESSING PIDS WITH WDS, START VEHICLE SESSION THEN SELECT: ^ Toolbox Icon ^ Datalogger, Then Tick (Check Mark) ^ Modules, Then Tick ^ PAM, Then Tick ^ Select The Appropriate PIDS, Then Tick WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 15K859 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings Parking Assist Distance Sensor: All Technical Service Bulletins Parking Assist System - False Warnings TSB 05-4-18 03/07/05 FALSE PARKING AID WARNINGS FORD: 1999-2001 Explorer, Windstar 2000-2001 Excursion, Expedition 2001 F-Super Duty LINCOLN: 2000-2001 Navigator MERCURY: 1999-2001 Mountaineer This article supersedes TSB 04-26-2 to update the vehicle lines and model years. ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This condition may also occur on vehicles equipped with the forward sensing system (FSS) when vehicle is in reverse or drive. ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before replacing any sensor(s). SERVICE TIPS NOTE THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS. OPERATION AND COMMON CAUSE OF WARNINGS The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the FSS the system is operational when the vehicle is in reverse or drive. The FSS and RSS give an audible warning to the driver when obstacles are within 6' (1.8 meters) from the vehicle, and when obstacles are within 18" (46 cm) on either side of the bumper. NOTE CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS COMPOSED OF. NOTE THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE EXCEPTION STATED IN THE NOTE ABOVE. NOTE THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT ADJUSTABLE. In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or give warnings for 3 seconds then ceases, the occurrence may be due to any of the following reasons: BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE: Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 9071 Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is contaminated with any foreign material the system may sound a continuous tone or intermittent tone. The sensor surface can be cleaned by a high pressure water spray. SIDE COVERAGE SENSOR: There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large, extending obstacle such as a garage wall. If there is no encroachment between any of the outer sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the obstacle begin to move closer to each other, then the warning will begin again. Obstacles within 10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal operation. ABNORMAL ROAD SURFACES: The RSS/FSS may give warnings due to certain road surfaces with surface projections such as rocks, broken pavement, unplowed snow covered roads. This is considered normal operation. OTHER POSSIBLE CAUSES: Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External ultrasonic noise may be detected (high velocity air, machinery). This is considered normal operation. SENSOR DIAGNOSTICS 1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and within 6' (1.8 meters) of the front of the vehicle for the FSS. 2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high pressure water wash to ensure that the membrane gap is free of any dirt or contamination. 3. Using the New Generation Star (NGS) tester or WDS, observe the following four (4) parking aid module parameter identification displays (PIDs) for distance information: ^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle) ^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle) ^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle) ^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle) NOTE PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED. a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches (NGS+ and WDS). b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation procedures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 9072 ACCESSING PIDS WITH NGS, SELECT: ^ Vehicle Line ^ Diagnostic Data Link ^ PAM ^ PID/Data Monitor And Record ^ Select the appropriate PIDS ^ Start ACCESSING PIDS WITH WDS, START VEHICLE SESSION THEN SELECT: ^ Toolbox Icon ^ Datalogger, Then Tick (Check Mark) ^ Modules, Then Tick ^ PAM, Then Tick ^ Select The Appropriate PIDS, Then Tick WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 15K859 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 9073 Parking Assist Distance Sensor: Specifications Azimuth System Check Object Position 1 (P1) and Position 5 (P5), Distance From Sensor 90 cm Azimuth System Check Object Position 2 (P2), 3 (P3) and Position 4 (P4), Distance From Sensor 160 cm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 9074 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 9075 Parking Assist Distance Sensor: Service and Repair REMOVAL 1. Remove the rear bumper. 2. Remove the parking aid sensor. 1 Disconnect the electrical connector. 2 Release the tabs. 3 Remove the parking aid sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Diagrams > Page 9079 Parking Assist Switch: Service and Repair REMOVAL 1. Remove the audio unit. For additional information, refer to Radio, Stereo, and Compact Disc. 2. Remove the center instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connector. 3. Remove the hood latch release handle. 1 Remove the screws. 2 Remove the hood latch release handle. 4. Remove the instrument panel lower steering column cover. 1 Remove the screws. 2 Remove the instrument panel lower steering column cover. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Diagrams > Page 9080 5. Remove the instrument panel steering column opening cover reinforcement. 1 Remove the screws. 2 Remove the instrument panel steering column opening cover reinforcement. 6. If equipped, position the column gearshift lever aside. 7. Remove the instrument cluster finish panel. 1 Remove the screws. 2 Remove the instrument cluster finish panel. ^ Disconnect the electrical connector. 8. Remove the parking aid switch. 1 Remove the screws. 2 Remove the parking aid switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair Remote Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the steering wheel controls. 1 Carefully remove the steering wheel controls. 2 Disconnect the steering wheel controls. NOTE: The steering wheel is leather wrapped and should be protected when removing the steering wheel controls. INSTALLATION 1. Install the steering wheel controls. 1 Connect the steering wheel controls. 2 Install the steering wheel controls. 2. Connect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9089 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9090 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9091 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9092 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9093 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9094 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9095 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9096 Trailer Connector: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9097 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9098 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9099 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9100 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9101 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9102 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9103 Trailer Connector: Electrical Diagrams Diagram 95-1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9104 Diagram 95-2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Trailer Lamps: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the trailer tow lights. 2. Verify the exterior lighting system of the vehicle is operating properly. If not, refer to the appropriate pinpoint test. 3. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Central Junction Box (CJB) Fuse 3 (7.5 A) ^ CJB Fuse 7 (7.5 A) ^ CJB Fuse 30 (15 A) ^ Loose or corroded connections ^ Damaged circuity ^ Damaged relays ^ Failed bulb(s) 4. If the fault is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9109 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9110 Trailer Lamps: Pinpoint Tests Connector Circuit Reference Refer to the Vehicle/Diagrams for schematic and connector information. AA1 - AA2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9111 AB1 - AB2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9112 AC1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9113 AD1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9114 AE1 - AE2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9115 73 Digital Multimeter Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9120 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9121 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9122 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9123 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9124 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9125 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9126 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9127 Trailer Connector: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9128 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9129 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9130 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9131 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9132 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9133 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9134 Trailer Connector: Electrical Diagrams Diagram 95-1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9135 Diagram 95-2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair Front Bumper Cover / Fascia: Service and Repair FRONT BUMPER COVER Removal and Installation 1. Remove the radiator grille sight shield. 1. Remove the bolts. 2. Release the retaining clips. 3. Remove the radiator grille sight shield. 2. Remove the two parking lamp assemblies. 1. Remove the two bolts (one each side). 2. Remove the two parking lamp assemblies. - Disconnect the electrical connectors. 3. Remove the two headlamp assemblies. 1. Pull upward to release the four tabs (two each side). 2. Remove the two headlamp assemblies. - Disconnect the electrical connectors. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Page 9142 4. Remove the three lower radiator air deflector bolts. 5. Remove the six fender splash shield screws (three each side). 6. Remove the two front bumper cover bolts from inside the fender opening (one each side). 7. Remove the front bumper cover. - Unclip the six locking tabs. 8. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair Front Bumper Reinforcement: Service and Repair FRONT BUMPER Removal and Installation 1. Remove the front bumper cover. 2. If equipped, remove the two fog lamp assemblies. 1. Disconnect the electrical connectors. 2. Remove the six bolts (three each side). 3. Remove the two fog lamp assemblies. 3. WARNING: To avoid possible injury, support the front bumper before removing the nuts. Remove the four nuts (two each side) and the front bumper. 4. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair Rear Bumper Cover / Fascia: Service and Repair REAR BUMPER COVER Special Tool(s) Special Tool(s) Removal and Installation 1. Disconnect the two license plate lamps. 2. Remove the four splash shield screws (two each side). 3. Remove the two rear bumper cover rivets (one each side). 4. NOTE: Align the rear bumper cover to the rear bumper beam guide holes when installing the step pads Remove the two step pads (one each side). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Page 9150 5. Remove the rear bumper cover. 6. To install, reverse the removal procedure. - Using the special tool, install the new rivets. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL PANEL GRILLE Removal and Installation 1. Disconnect the driver side windshield washer hose from inside the engine compartment. 2. Remove the windshield wiper pivot arms. 1. Slide the clip so the windshield wiper pivot arm will clear the windshield wiper pivot shaft. 2. Pull the windshield wiper pivot arm from the windshield wiper pivot shaft. 3. Remove the cowl grille screw. 4. Remove the driver side cowl grille. - Pull up on the cowl grille to disengage the clips. 5. Remove the passenger side cowl grille. - Pull up on the cowl grille to disengage the clips and disconnect the washer hose. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair Heavy Duty Riveter SPECIAL SERVICE TOOLS REMOVAL NOTE: Front door shown, rear door similar. 1. Remove the door trim panel. 2. Remove the watershield. 3. Remove the outside door handle. 1 Disconnect the front door latch to door handle rod. 2 Drill out the two rivets and remove the outside door handle. NOTE: The front door window glass must be completely up. INSTALLATION 1. To install, reverse the removal procedure. - Use Heavy-Duty Riveter to install the rivets. NOTE: Front door shown, rear door similar. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Page 9162 Heavy Duty Riveter Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair Front Door Interior Handle: Service and Repair REMOVAL NOTE: Front door shown, rear door similar. 1. Remove the door trim panel. 2. Disconnect the inside door handle from the door. 1 Remove the screws. 2 Disconnect the inside door handle. 3. Disconnect the rod from the inside door handle. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Front door shown, rear door similar. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Specifications Front Door Latch: Specifications Door Latch Screws 4-8 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Specifications > Page 9169 Door Latch Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Specifications > Page 9170 Door Latch Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Specifications > Page 9171 Front Door Latch: Service and Repair REMOVAL NOTE: Front door shown, rear door similar. 1. Disconnect the battery ground cable. 2. If removing the front door latch, remove the door lock cylinder; refer to Lock Cylinder-Door. 3. Remove the door trim panel. 4. Remove the door latch remote control. 1 Remove the screws. 2 Disconnect the door latch remote control link from the door latch remote control. 3 Remove the door latch remote control. 5. Disconnect the door latch actuating rod from the door latch. 6. Remove the rear glass run channel. 1 Remove the bolt. 2 Remove the rear glass run channel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Specifications > Page 9172 7. Remove the door latch. 1 Remove the screws. 2 Disconnect the door latch from the power door lock actuator. 3 Remove the door latch. 8. Disconnect the door latch push button rod from the door latch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Front door shown, rear door similar. - Connect the remote control rod, door latch push button rod and lock cylinder rod to the front door latch before installing the new latch. - When the battery is disconnected or reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Specifications > Page 9173 The vehicle may need to be driven 16km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair Front Door Panel: Service and Repair TRIM PANEL - FRONT DOOR Removal NOTE: High series shown, low series similar. - The window must be completely down to remove the front door trim panel. 1. On high series front door trim panel, disconnect the battery ground cable (14301). 2. Remove the screws. 3. Remove the inside door handle cup (22634). 4. On low series front door trim panel, remove the screw and the window regulator handle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Page 9177 5. Start in a lower corner and work around the panel and separate the front door trim panel (23942) from the front door (20124) to disengage the pin-type retainers. 6. Lift the front door trim panel to disengage the top lip from the weatherstrip. 7. Position the front door trim panel aside. 8. Separate the power window switch finish panel from the door trim panel. - Release the locking tabs. 9. If equipped, remove the courtesy lamp bulb from the lens and remove the front door trim panel. Installation 1. NOTE: When the battery (10653) is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair Heavy Duty Riverter SPECIAL SERVICE TOOL(S) REMOVAL 1. Remove the front door trim panel. 2. Remove the inside glass weatherstrip. 3. Drill out the window regulator arm to window glass rivets. NOTE: Lower the window glass to access the two rivets. 4. Remove the front door window glass. NOTE: Slide the glass through the outboard side of the front door. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair > Page 9181 INSTALLATION 1. Position the front door window glass. NOTE: Slide the glass through the outboard side of the front door. 2. Use Heavy Duty Riveter to install the window regulator arm to window glass rivets. 3. Install the inside glass weatherstrip. 4. Install the front door trim panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Specifications Front Door Window Motor: Specifications Power Window Motor Nuts 5.6-9.1 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Specifications > Page 9185 Front Door Window Motor: Service Precautions WARNING: PRIOR TO POWER WINDOW REMOVAL, ENSURE THE REGULATOR ARMS ARE IN A FIXED POSITION TO PREVENT COUNTERBALANCE SPRING UNWIND. FAILURE TO PLACE THE REGULATOR ARMS IN A FIXED POSITION CAN CAUSE THE SPRING TO SUDDENLY RELEASE RESULTING IN PERSONAL INJURY. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Specifications > Page 9186 Front Door Window Motor: Service and Repair Heavy Duty Riverter SPECIAL SERVICE TOOLS REMOVAL 1. Raise the front door window glass to the full up position. 2. Remove the front door trim panel. 3. Disconnect the battery ground cable. 4. Disconnect the inside front door handle from the front door. 1 Remove the screws. 2 Disconnect the inside front door handle. 5. Disconnect the rod from the inside front door handle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Specifications > Page 9187 6. Support the front door window glass. 7. If equipped, disconnect the power window motor electrical connector. 8. If equipped, remove the equalizer bracket to front door inner panel nuts. 9. Remove the window regulator/motor assembly. 1 Drill out the rivets. 2 Remove the nut. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Specifications > Page 9188 10. If equipped, remove the power window motor. 1 Remove the bolts. 2 Remove the power window motor. WARNING: PRIOR TO POWER WINDOW REMOVAL, ENSURE THE REGULATOR ARMS ARE IN A FIXED POSITION TO PREVENT COUNTERBALANCE SPRING UNWIND. FAILURE TO PLACE THE REGULATOR ARMS IN A FIXED POSITION CAN CAUSE THE SPRING TO SUDDENLY RELEASE RESULTING IN PERSONAL INJURY. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Specifications > Page 9189 1. To install, reverse the removal procedure. ^ Use Heavy Duty Riveter to install the new rivets. ^ Cycle the door glass to ensure engagement of the drive mechanism. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Specifications > Page 9190 Heavy Duty Riveter Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Specifications Front Door Window Regulator: Specifications Rear Window Glass Regulator Nut 10-14 Nm Window Regulator Switch Plate Harness Assembly 2-3 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Specifications > Page 9194 Front Door Window Regulator: Service Precautions WARNING: PRIOR TO POWER WINDOW REMOVAL, ENSURE THE REGULATOR ARMS ARE IN A FIXED POSITION TO PREVENT COUNTERBALANCE SPRING UNWIND. FAILURE TO PLACE THE REGULATOR ARMS IN A FIXED POSITION CAN CAUSE THE SPRING TO SUDDENLY RELEASE RESULTING IN PERSONAL INJURY. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Specifications > Page 9195 Front Door Window Regulator: Service and Repair Heavy Duty Riverter SPECIAL SERVICE TOOLS Motor and Window Regulator - Front Door REMOVAL 1. Raise the front door window glass to the full up position. 2. Remove the front door trim panel. 3. Disconnect the battery ground cable. 4. Disconnect the inside front door handle from the front door. 1 Remove the screws. 2 Disconnect the inside front door handle. 5. Disconnect the rod from the inside front door handle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Specifications > Page 9196 6. Support the front door window glass. 7. If equipped, disconnect the power window motor electrical connector. 8. If equipped, remove the equalizer bracket to front door inner panel nuts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Specifications > Page 9197 9. Remove the window regulator/motor assembly. 1 Drill out the rivets. 2 Remove the nut. 10. If equipped, remove the power window motor. 1 Remove the bolts. 2 Remove the power window motor. WARNING: PRIOR TO POWER WINDOW REMOVAL, ENSURE THE REGULATOR ARMS ARE IN A FIXED POSITION TO PREVENT COUNTERBALANCE SPRING UNWIND. FAILURE TO PLACE THE REGULATOR ARMS IN A FIXED POSITION CAN CAUSE THE SPRING TO SUDDENLY RELEASE RESULTING IN PERSONAL INJURY. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Specifications > Page 9198 1. To install, reverse the removal procedure. ^ Use Heavy Duty Riveter to install the new rivets. ^ Cycle the door glass to ensure engagement of the drive mechanism. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Specifications > Page 9199 Heavy Duty Riveter Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair Rear Door Exterior Handle: Service and Repair Heavy Duty Riveter SPECIAL SERVICE TOOLS REMOVAL NOTE: Front door shown, rear door similar. 1. Remove the door trim panel. 2. Remove the watershield. 3. Remove the outside door handle. 1 Disconnect the front door latch to door handle rod. 2 Drill out the two rivets and remove the outside door handle. NOTE: The front door window glass must be completely up. INSTALLATION 1. To install, reverse the removal procedure. - Use Heavy-Duty Riveter to install the rivets. NOTE: Front door shown, rear door similar. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair Rear Door Interior Handle: Service and Repair REMOVAL NOTE: Front door shown, rear door similar. 1. Remove the door trim panel. 2. Disconnect the inside door handle from the door. 1 Remove the screws. 2 Disconnect the inside door handle. 3. Disconnect the rod from the inside door handle. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Front door shown, rear door similar. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Specifications Rear Door Latch: Specifications Door Latch Screws 4-8 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Specifications > Page 9211 Door Latch Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Specifications > Page 9212 Rear Door Latch: Service and Repair REMOVAL NOTE: Front door shown, rear door similar. 1. Disconnect the battery ground cable. 2. If removing the front door latch, remove the door lock cylinder; refer to Lock Cylinder-Door. 3. Remove the door trim panel. 4. Remove the door latch remote control. 1 Remove the screws. 2 Disconnect the door latch remote control link from the door latch remote control. 3 Remove the door latch remote control. 5. Disconnect the door latch actuating rod from the door latch. 6. Remove the rear glass run channel. 1 Remove the bolt. 2 Remove the rear glass run channel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Specifications > Page 9213 7. Remove the door latch. 1 Remove the screws. 2 Disconnect the door latch from the power door lock actuator. 3 Remove the door latch. 8. Disconnect the door latch push button rod from the door latch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Front door shown, rear door similar. - Connect the remote control rod, door latch push button rod and lock cylinder rod to the front door latch before installing the new latch. - When the battery is disconnected or reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Specifications > Page 9214 The vehicle may need to be driven 16km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair Rear Door Panel: Service and Repair TRIM PANEL - REAR DOOR Removal NOTE: High series shown, low series similar. - The window glass must be completely down to remove the rear door trim panel. 1. Remove the screws. 2. Remove the inside door handle cup. 3. On low series rear door trim panel, remove the window regulator handle. - Remove the screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Page 9218 4. Start in a lower corner and work around the panel and separate the rear door trim panel from the rear door to disengage the pin-type retainers. 5. Remove the rear door trim panel by lifting to disengage the top lip from the weatherstrip. 6. Turn the rear door trim panel over. 7. Disconnect the power window switch electrical connector. 1. Remove the screws. 2. Disconnect the electrical connector. Installation 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair Heavy Duty Riverter SPECIAL SERVICE TOOL(S) REMOVAL 1. Remove the rear door trim panel. 2. Remove the inside glass weatherstrip. 3. Drill out the window regulator arm to window glass rivets. 4. Remove the rear door window glass. NOTE: Slide the glass through the outboard side of the rear door. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair > Page 9222 1. Position the rear door window glass. NOTE: Slide the glass through the outboard side of the rear door. 2. Use Heavy Duty Riveter to install the window regulator arm to window glass rivets. 3. Install the inside glass weatherstrip. 4. Install the rear door trim panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Specifications Rear Door Window Motor: Specifications Power Window Motor Nuts 5.6-9.1 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Specifications > Page 9226 Rear Door Window Motor: Service Precautions WARNING: PRIOR TO POWER WINDOW REMOVAL, ENSURE THE REGULATOR ARMS ARE IN A FIXED POSITION TO PREVENT COUNTERBALANCE SPRING UNWIND. FAILURE TO PLACE THE REGULATOR ARMS IN A FIXED POSITION CAN CAUSE THE SPRING TO SUDDENLY RELEASE RESULTING IN PERSONAL INJURY. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Specifications > Page 9227 Rear Door Window Motor: Service and Repair REMOVAL 1. Raise and support the rear door window glass to the full up position. 2. Disconnect the battery ground cable. 3. Remove the rear door trim panel. 4. Remove the speaker. 1 Remove the screws. 2 Disconnect the electrical connector. 3 Remove the speaker. 5. Remove the watershield. 6. Remove the power window motor. 1 Remove the bolts. 2 Disconnect the electrical connector. 3 Remove the power window motor. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Specifications > Page 9228 1. To install, reverse the removal procedure. ^ Cycle the door glass to ensure engagement of the drive mechanism. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Specifications > Page 9229 Heavy Duty Riveter Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Specifications Rear Door Window Regulator: Specifications Rear Window Glass Regulator Nut 10-14 Nm Window Regulator Switch Plate Harness Assembly 2-3 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Specifications > Page 9233 Rear Door Window Regulator: Service and Repair Heavy Duty Riverter SPECIAL SERVICE TOOLS REMOVAL 1. Remove the rear door trim panel. 2. Disconnect the inside rear door handle from the rear door. 1 Remove the screws. 2 Disconnect the inside rear door handle. 3. Disconnect the rod from the inside rear door handle. 4. Remove the speaker. 1 Remove the screws. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Specifications > Page 9234 2 Disconnect the electrical connector. 3 Remove the speaker. 5. Remove the watershield. 6. Raise and support the rear door window glass to the full up position. 7. Disconnect the battery ground cable. 8. If equipped, disconnect the power window electrical connector. 9. Drill out the window regulator rivets. 10. Remove the rear door window regulator. ^ Slide the regulator arms off of the window glass track. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Specifications > Page 9235 1. To install, reverse the removal procedure. ^ Use Heavy Duty Riveter to install the new rivets. ^ Cycle the door glass to ensure engagement of the drive mechanism. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Specifications > Page 9236 Heavy Duty Riveter Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Specifications Hood Latch: Specifications Hood Latch Bolts 10.5-13.5 Nm Hood Latch Control Handle Screws 2-4 Nm Hood Latch Release Handle Screws 2.7-3.7 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Specifications > Page 9241 Hood Latch Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Specifications > Page 9242 Hood Latch: Adjustments 1. Verify the hood alignment. 2. Remove the radiator grille sight shield. 1 Remove the bolts. 2 Remove the rivets. 3 Remove the radiator grille sight shield. 3. Align the hood latch. 1 Loosen the hood latch bolts enough to allow for movement of the hood latch. 2 Align the hood latch with the hood latch striker. 4. Tighten the hood latch bolts. 5. Verify the hood latch striker is fully engaging the hood latch. - Repeat the procedure as necessary. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Specifications > Page 9243 Hood Latch: Service and Repair REMOVAL 1. Raise and support the hood. 2. Remove the radiator grille sight shield. 1 Remove the bolts. 2 Remove the rivets. 3 Remove the radiator grille sight shield. 3. Remove the hood latch. 1 Remove the bolts. 2 Disconnect the hood latch cable from the hood latch. 3 Remove the hood latch. NOTE: Mark the hood latch position prior to removal of the bolts. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Specifications > Page 9244 1. To install, reverse the removal procedure. - Adjust the hood latch; refer to Latch-Hood, Adjustment. See: Adjustments Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Locations Hood Latch Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Locations > Page 9248 Hood Latch Release Cable: Service and Repair REMOVAL NOTE: The hood latch control handle and cable are replaced as an assembly. 1. Remove the hood latch. For additional information, refer to Hood Latch. 2. Unclip the hood latch control handle and cable retainer from the inner fender splash shield. 3. Position the hood latch control handle and cable aside. 1 Remove the two screws. 2 Position the hood latch control handle and cable aside. 4. Remove the hood latch control handle and cable. 1 Remove the hood latch control and cable grommet from the dash panel. 2 Remove the hood latch control handle and cable. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Locations > Page 9249 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 SOHC VIN K SFI (2001)) 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 9255 OASIS CODES: 201000, 201200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair REMOVAL 1. Open the liftgate glass. 2. Disconnect the two rear window defogger electrical connectors (one on each side). 3. Disconnect the two liftgate cylinders (one on each side). 4. Release the upper liftgate trim panel clips to gain access to liftgate window glass access plugs. 5. Remove the liftgate glass hinge access plugs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Page 9260 6. Remove the liftgate window glass. 1 Remove the two liftgate window glass to window hinge nuts. 2 Remove the liftgate window glass. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations Liftgate Latch Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Page 9264 Power Trunk / Liftgate Lock Actuator: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the liftgate window latch. For additional information, refer to Liftgate Window Latch. 3. Remove the vent panel. 1 Remove the pin-type retainers. 2 Remove the vent panel. 4. Disconnect the liftgate latch release rods. 1 Open the clips. 2 Disconnect the liftgate latch release rods. 5. Disconnect the liftgate handle rod. 1 Open the clip. 2 Disconnect the liftgate handle rod. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Page 9265 6. Disconnect the lock cylinder rod. 1 Open the clip. 2 Disconnect the lock cylinder rod. 7. Remove the liftgate latch remote control bolt. 8. Disconnect the liftgate lock actuator electrical connector. 9. Remove the liftgate lock actuator nuts. 10. Move the liftgate latch remote control to the LH opening and remove the liftgate lock actuator. INSTALLATION 1. Connect and position the liftgate lock actuator. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Page 9266 2. Install the liftgate lock actuator nuts. 3. Connect the liftgate lock actuator electrical connector. 4. Position the liftgate latch remote control. 5. Loosely install the liftgate latch remote control bolt. 6. Install the liftgate window latch. 1 Position the liftgate window latch. 2 Install the nuts. 3 Connect the electrical connector. NOTE: Manually close the liftgate window latch to set the latch control rod length. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Page 9267 7. Connect the liftgate window latch actuating rod. 1 Position the liftgate window latch actuating rod. 2 Close the clip. 8. Tighten the liftgate latch remote control bolt. 9. Connect the lock cylinder rod. 1 Position the lock cylinder rod. 2 Close the clip. NOTE: Be sure the bell crank of the liftgate latch remote control is in the unlocked position (upward) for proper lock cylinder rod length. 10. Connect the liftgate handle rod. 1 Position the liftgate handle rod. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Page 9268 2 Close the clip. NOTE: Make sure the liftgate handle rod is not preloading the liftgate latch remote control. It should be clipped in a relaxed state with no slack. 11. Connect the liftgate latch release rods. 1 Position the liftgate latch release rods by pushing outboard to remove the slack. 2 Close the clips. NOTE: Make sure the latch release rods are not pre loading the liftgate latch. They should be clipped in a relaxed state with no slack. 12. Install the vent panel. 1 Position the vent panel. 2 Install the pin-type retainers. 13. Adjust the liftgate window latch. For additional information, refer to Liftgate Latch, Adjustment. See: Trunk / Liftgate Latch/Adjustments 14. Install the liftgate watershield. 15. Install the liftgate trim panel. 16. Connect the battery ground cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Locations Liftgate Latch Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Locations > Page 9272 Trunk / Liftgate Handle: Service and Repair Heavy Duty Riveter SPECIAL SERVICE TOOLS REMOVAL 1. Remove the liftgate trim panel. 2. Remove the liftgate watershield. 3. Remove the vent panel. 1 Remove the pin-type retainers. 2 Remove the vent panel. 4. Disconnect the outside liftgate handle actuating rod. 1 Open the clip. 2 Disconnect the outside liftgate handle actuating rod. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Locations > Page 9273 5. Remove the license plate lamp shield 1 Remove the screws. 2 Remove the license plate lamp shield. 6. Remove the outside liftgate handle. 1 Drill out the rivets. 2 Remove the outside liftgate handle. INSTALLATION 1. To install, reverse the removal procedure. Use Heavy-Duty Riveter to install the rivets. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Locations > Page 9274 Heavy Duty Riveter Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Specifications Trunk / Liftgate Latch: Specifications Liftgate Latch Bolt 9-14 Nm Liftgate Latch Remote Control 11-13 Nm Liftgate Window Latch Nuts 12 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Specifications > Page 9278 Liftgate Latch Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Specifications > Page 9279 Trunk / Liftgate Latch: Adjustments 1. Remove the liftgate trim panel. 2. Remove the liftgate watershield. 3. Close the liftgate window glass. 4. Disconnect the liftgate window latch actuating rod. 1 Open the clip. 2 Disconnect the liftgate window latch actuating rod. 5. Loosen the liftgate window latch nuts. 6. Adjust the liftgate window latch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Specifications > Page 9280 - Set the liftgate window glass flushness to 1.5 mm (0.06 in) under flush. 7. Tighten the liftgate window latch nuts. 8. Connect the liftgate window latch activating rod. 1 Connect the liftgate window latch actuating rod. 2 Lock the clip. 9. Verify the liftgate window glass flushness. 10. Install the liftgate watershield. 11. Install, the liftgate trim panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch Trunk / Liftgate Latch: Service and Repair Liftgate Latch REMOVAL 1. Remove the liftgate trim panel. 2. Remove the liftgate watershield. 3. Disconnect the liftgate latch release rod from the liftgate latch remote control. 1 Open the clip. 2 Disconnect the liftgate latch release rod. 4. Remove the liftgate latch. 1 Remove the bolts. 2 Disconnect the electrical connector. 3 Remove the liftgate latch and the liftgate release rod. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 9283 1. To install, reverse the removal procedure. NOTE: If replacement of the liftgate latch release rods necessary, be sure to match the color coded rods for proper installation. - Make sure the liftgate latch release rod is not preloading the latch. It should be clipped in a relaxed state with no slack. - Position the liftgate latch release rod by pushing outboard to remove the slack. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 9284 Trunk / Liftgate Latch: Service and Repair Liftgate Latch Remote Control REMOVAL NOTE: If equipped with power locks, perform steps one and eight. 1. Remove the liftgate lock actuator. For additional information, refer to Liftgate Lock Actuator. 2. Remove the liftgate window latch. For additional information, refer to Liftgate Latch. 3. Remove the vent panel. 1 Remove the pin-type retainers. 2 Remove the vent panel. 4. Disconnect the liftgate latch release rods. 1 Open the clips. 2 Disconnect the liftgate latch release rods. 5. Disconnect the liftgate handle rod. 1 Open the clip. 2 Disconnect the liftgate handle rod. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 9285 6. Disconnect the lock cylinder rod. 1 Open the clip. 2 Disconnect the lock cylinder rod. 7. Remove the liftgate latch remote control bolt. 8. Remove the liftgate latch remote control from the liftgate. INSTALLATION NOTE: If equipped with power locks, perform steps one and two. 1. Install the latch remote control and (if equipped) the push button rod into the liftgate. 2. Install the liftgate lock actuator. For additional information, refer to Liftgate Lock Actuator. 3. Loosely install the liftgate latch remote control bolt. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 9286 4. Install the liftgate window latch. 1 Position the liftgate window latch. 2 Install the nuts. 3 Connect the electrical connector. NOTE: Manually close the liftgate window latch to set the latch control rod length. 5. Connect the liftgate window latch actuating rod. 1 Position the liftgate window latch actuating rod. 2 Close the clip. 6. Tighten the liftgate latch remote control bolt. 7. Connect the lock cylinder rod. 1 Position the lock cylinder rod. 2 Close the clip. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 9287 8. Connect the liftgate handle rod. 1 Position the liftgate handle rod. 2 Close the clip. NOTE: Make sure the liftgate handle rod is not preloading the liftgate latch remote control. It should be clipped in a relaxed state with no slack. 9. Connect the liftgate latch release rods. 1 Position the liftgate latch release rods by pushing outboard to remove the slack. 2 Close the clips. NOTE: Make sure the latch release rods are not preloading the liftgate latch remote control. They should be clipped in a relaxed state with no slack. 10. Install the vent panel. 1 Position the vent panel. 2 Install the pin-type retainers. 11. Adjust the liftgate window latch. For additional information, refer to Liftgate Window Latch, Adjustment. See: Adjustments Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 9288 12. Install the liftgate watershield. 13. Install the liftgate trim panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 9289 Trunk / Liftgate Latch: Service and Repair Liftgate window Latch REMOVAL 1. Open the liftgate window glass. 2. Remove the liftgate trim panel. 3. Remove the liftgate watershield. 4. Disconnect the liftgate window latch actuating rod. 1 Open the clip. 2 Disconnect the liftgate window latch actuating rod. 5. Disconnect the electrical connector and remove the nuts. NOTE: Mark the position of the liftgate window latch prior to removing the nuts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Latch > Page 9290 6. Remove the liftgate window latch. INSTALLATION 1. To install, reverse the removal procedure. Before installing the liftgate trim panel, adjust the liftgate window latch; refer to Liftgate Window Latch, Adjustment. See: Adjustments NOTE: Manually close the liftgate window latch to set the latch control rod length. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Specifications Trunk / Liftgate Lock Cylinder: Specifications Liftgate Lock Cylinder Nuts 6-7 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Specifications > Page 9294 Liftgate Latch Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Specifications > Page 9295 Trunk / Liftgate Lock Cylinder: Service and Repair REMOVAL NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. 1. If equipped, remove the liftgate lock actuator. For additional information, refer to Liftgate Lock Actuator. 2. Remove the liftgate latch remote control. For additional information, refer to Liftgate Latch. 3. Remove the liftgate lock cylinder. 1 Remove the nuts. 2 Remove the liftgate lock cylinder. If equipped, disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Manually close the liftgate window latch to set the latch control rod length. - Make sure the liftgate window latch actuating rod is not preloading the liftgate window latch. It should be clipped in a relaxed state with no slack. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams > Page 9299 Trunk / Liftgate Switch: Testing and Inspection Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams > Page 9300 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL PANEL GRILLE Removal and Installation 1. Disconnect the driver side windshield washer hose from inside the engine compartment. 2. Remove the windshield wiper pivot arms. 1. Slide the clip so the windshield wiper pivot arm will clear the windshield wiper pivot shaft. 2. Pull the windshield wiper pivot arm from the windshield wiper pivot shaft. 3. Remove the cowl grille screw. 4. Remove the driver side cowl grille. - Pull up on the cowl grille to disengage the clips. 5. Remove the passenger side cowl grille. - Pull up on the cowl grille to disengage the clips and disconnect the washer hose. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair Front Fender Liner: Service and Repair FENDER SPLASH SHIELD Removal and Installation Both Sides 1. Remove the fender splash shield front bolts. 2. Remove the fender splash shield screws. LH Side 3. From inside the engine compartment, disconnect the wiring harness retainers from the fender splash shield. 4. Remove the ABS module nut. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Page 9310 RH Side 5. Position the vacuum reservoir aside. 1. Remove the bolts. 2. Position the vacuum reservoir aside. 6. Remove the fender splash shield bolts. Both Sides 7. Remove the fender splash shield. 8. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 Body / Frame Mount Bushing: Service and Repair Body Support - Number 1 BODY SUPPORT - NUMBER 1 Materials Material Removal and Installation NOTE: Left side shown, right side similar. Upper and Lower Insulator 1. Remove the door scuff plate. 2. Remove the A-pillar lower trim panel. 1. Remove the pin-type retainer. 2. Remove the A-pillar lower trim panel. 3. Position back the carpeting and remove the body insulator plug. 4. NOTE: This step may require holding the lower retainer with an appropriate tool. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 9316 Remove the body mount insulator bolt. 5. NOTE: If the lower body mount will not remove, loosely install the body mount bolt and tap on the body mount bolt head with a hammer. Remove the lower body mount insulator. Upper Insulator 6. Loosen, but do not remove, all the remaining body mount insulator bolts. 7. Carefully raise the vehicle body enough to remove the upper body mount insulator. Upper and Lower Insulator 8. NOTE: - Apply Threadlock 262 E2FZ-19554-B meeting Ford specification WSK-M2G351-A6 or equivalent to the mounting bolt. - No lubricants of any kind are to be used during body insulator installation. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 9317 Body / Frame Mount Bushing: Service and Repair Body Support - Number 2 BODY SUPPORT - NUMBER 2 Materials Material Removal and Installation NOTE: Left side shown, right side similar. Upper and Lower Insulator 1. Position the front seat forward. 2. Remove the door scuff plates. 3. Position back the carpeting and remove the body insulator plug. 4. NOTE: This step may require holding the lower retainer with an appropriate tool. Remove the body mount insulator bolt. 5. NOTE: If the lower body mount will not remove, loosely install the body mount bolt and tap on the body mount bolt head with a hammer. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 9318 Remove the lower body mount insulator. Upper Insulator 6. Loosen, but do not remove, all the remaining body mount insulator bolts. 7. Carefully raise the vehicle body enough to remove the upper body mount insulator. Upper and Lower Insulator 8. NOTE: - Apply Threadlock 262 E2FZ-19554-B meeting Ford specification WSK-M2G351-A6 or equivalent to the mounting bolt. - No lubricants of any kind are to be used during body insulator installation. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 9319 Body / Frame Mount Bushing: Service and Repair Body Support - Number 3 BODY SUPPORT - NUMBER 3 Materials Material Removal and Installation NOTE: Left side shown, right side similar. Upper and Lower Insulator - All Vehicles 1. Fold the rear seat forward. Upper and Lower Insulator - Explorer Sport 2. Position the carpet aside. Upper and Lower Insulator - Sport Trac 3. Open the storage compartment. Upper and Lower Insulator - All Vehicles 4. Remove the body insulator plug 5. NOTE: This step may require holding the lower retainer with an appropriate tool. Remove the body mount insulator bolt. Lower Insulator - All Vehicles Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 9320 6. NOTE: If the lower body mount will not remove, loosely install the body mount bolt and tap on the body mount bolt head with a hammer. Remove the lower body mount insulator. Upper Insulator - All Vehicles 7. Carefully raise the vehicle body enough to remove the upper body mount insulator. Upper and Lower Insulator - All Vehicles 8. NOTE: - Apply Threadlock 262 E2FZ-19554-B meeting Ford specification WSK-M2G351-A6 or equivalent to the mounting bolt. - No lubricants of any kind are to be used during body insulator installation. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 9321 Body / Frame Mount Bushing: Service and Repair Body Support - Number 4 BODY SUPPORT - NUMBER 4 Materials Material Removal and Installation NOTE: Left side shown, right side similar. Upper and Lower Insulator 1. Remove the liftgate scuff plate. 1. Release the locking tabs. 2. Remove the scuff plate. 2. NOTE: This step may require holding the lower retainer with an appropriate tool. Position back the carpeting and remove the body mount insulator bolt. 3. NOTE: If the lower body mount will not remove, loosely install the body mount bolt and tap on the body mount bolt head with a hammer. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 9322 Remove the lower body mount insulator. Upper Insulator 4. Loosen, but do not remove, all the remaining body mount insulator bolts. 5. Carefully raise the vehicle body enough to remove the upper body mount insulator. Upper and Lower Insulator 6. NOTE: - Apply Threadlock 262 E2FZ-19554-B meeting Ford specification WSK-M2G351-A6 or equivalent to the mounting bolt. - No lubricants of any kind are to be used during body insulator installation. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Support - Number 1 > Page 9323 Body / Frame Mount Bushing: Service and Repair Body Support - Radiator Support BODY SUPPORT - RADIATOR SUPPORT Removal and Installation NOTE: Left side shown, right side similar. Upper and Lower Insulator 1. From inside the engine compartment, remove the body mount insulator nut and backing plate and discard the nut. Lower Insulator 2. Remove the lower radiator body mount. 1. Remove the lower body mount bolt and discard. 2. Remove the lower body mount. Upper and Lower Insulator 3. Carefully raise the vehicle body enough to remove the upper radiator body mount insulator. 4. NOTE: - Do not reuse body support mounting fasteners. New fasteners must be installed for each fastener that has been removed or loosened. - No lubricants of any kind are to be used during body insulator installation. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information > Service and Repair Rear Cross-Member: Service and Repair CROSSMEMBER - TRANSMISSION SUPPORT Materials Materials Removal and Installation 1. Raise and support the vehicle. 2. Loosen, but do not remove, the nuts retaining the transmission insulator to the crossmember. 3. Support the transmission. 4. Remove the six bolts retaining the crossmember to the frame. 5. Remove the nuts and the crossmember. 6. NOTE: Apply Threadlock 262 E2FZ-19554-B meeting Ford specification WSK-M2G351-A6 or equivalent to the transmission crossmember mounting bolts. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair Grille: Service and Repair RADIATOR GRILLE Removal and Installation 1. Remove the front bumper cover. 2. Remove the radiator grilles. 1. Remove the four pin-type retainers. 2. Release the six clips. 3. Remove the radiator grilles. 3. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Specifications Console: Specifications Base Series Floor Console Rear Screw 2-3 Nm Base Series Floor Console Front Screws 3-4 Nm Upper Series Floor Console Bolts 9 Nm Upper Series Floor Console Electrical Connector Bolt 4.0-5.5 Nm Upper Series Front Floor Console Bolts 3.4-4.6 Nm Console Compartment Trim Panel Screw 2-3 Nm Console Glove Compartment Door Hinge Screw 2-3 Nm Console Rear Panel Screw 1.2-1.8 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Specifications > Page 9335 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Specifications > Page 9336 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console, Upper Series Console: Service and Repair Floor Console, Upper Series REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front floor console tray. - If equipped with message center, disconnect the three connectors. 3. Disconnect the floor console electrical connector. 1 Remove the bolt. 2 Disconnect the electrical connector. 4. Remove the front floor console bolts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console, Upper Series > Page 9339 5. Remove the center cupholder panel. 6. Remove the center floor console bolts. 7. Remove the floor console. NOTE: The console must be moved rearward to disengage the rear mounting bracket. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console, Upper Series > Page 9340 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console, Upper Series > Page 9341 Console: Service and Repair Floor Console, Base Series REMOVAL NOTE: The base floor console is shown; floor console with removable storage bin is similar. 1. Remove the front seat center armrest. 1 Remove the two covers. 2 Remove the four bolts. 3 Remove the armrest. 2. Remove the utility tray beverage holder. 3. Remove the floor console. 1 Remove the screws. 2 Remove the floor console. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console, Upper Series > Page 9342 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console, Upper Series > Page 9343 Console: Service and Repair Overhead Console REMOVAL 1. Disconnect the battery ground cable. 2. If equipped, open the garage door remote cover. 3. If equipped, remove the screws. 4. Remove the overhead console. 5. Disconnect the two electrical connectors (three connectors on moonroof equipped vehicles). INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING:To reduce the risk of personal injury, do not use any memory saver devices. NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram See: Restraint Systems/Air Bag Systems. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Disarming and Arming > Page 9349 7. Remove the two steering wheel back cover plugs. 8. Remove the two driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. 10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical connector at the clockspring. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Disarming and Arming > Page 9350 11. Open the glove compartment door to access the passenger air bag module mounting screws. 12. Remove the two screws. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove box opening, push out on the passenger air bag module and separate it from the instrument panel. 14. Disconnect the electrical connector and remove the passenger air bag module. 15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the passenger air bag module electrical connector. Vehicles equipped with seat side air bags Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Disarming and Arming > Page 9351 16. Disconnect the passenger seat side air bag module electrical connector located under the passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector located under the driver seat. 19. Connect the restraint system diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical connector. All vehicles 20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground cable. Reactivation Procedure All vehicles 1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles equipped with seat side air bags 3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side air bag module electrical connector located under the driver seat. 4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint system diagnostic tool from the body harness side of the passenger seat side air bag module electrical connector located under the passenger seat. 6. Connect the passenger seat side air bag module electrical connector All vehicles 7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air bag module electrical connector. 8. Install the passenger air bag module. 9. Connect the passenger air bag module electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Disarming and Arming > Page 9352 10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical connector at the clockspring. 11. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag module to the steering wheel. 12. Install the two driver air bag module retaining bolts. 13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON. 15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 17. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Disarming and Arming > Page 9353 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle battery connected? Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Disarming and Arming > Page 9354 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Prove out the system means to turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair Headliner: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the quarter trim panel. 3. If equipped, remove the overhead console. 4. Remove the interior lamps. 5. Remove the sun visors. 1 Remove the six screws. 2 Remove the sun visors. If equipped, disconnect the electrical connectors. 6. Remove the sun visor brackets. 1 Remove the two screws. 2 Remove the sun visor brackets. 7. Remove the assist handle bolt covers. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 9358 8. Remove the assist handles. 1 Remove the bolts. 2 Remove the assist handles. 9. Remove the headliner pin-type retainers. 10. Remove the six remaining pin-type retainers. 11. Remove the headliner. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair Sun Visor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the sun visor. - Position the sun visor as necessary. - Remove the sun visor screws. 3. Lower the sun visor and disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel Trim Panel: Service and Repair A-Pillar Trim Panel Special Service Tool(s) SPECIAL SERVICE TOOL(S) REMOVAL 1. Remove the windshield side garnish moulding. 2. Remove the front door scuff plate. 1 Starting at one end and working along the front door scuff plate, use Windshield and Molding/Trim Removal Kit to remove the front door scuff plate. 2 Remove the front door scuff plate from the B-pillar. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 9366 3. Remove the (A) screw and the (B) coat hook. 4. Open the front safety belt guide bolt cover. 5. Using special tool, remove the front safety belt guide bolt. 6. Use Safety Belt Bolt Bit to remove the front safety belt anchor bolt. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 9367 7. Remove the B-pillar trim panel. 1 Remove the pin-type retainer. 2 Feed the safety belt webbing through the opening. 3 Remove the B-pillar trim panel. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 9368 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 9369 Trim Panel: Service and Repair Cowl Side Trim Panel Windshield and Molding/Trim Removal Kit Or Equivalent Special Service Tool(s) REMOVAL NOTE: 4-door shown, 2-door similar. 1. Remove the front door scuff plate. 1 Starting at one end and working along the front door scuff plate, use Windshield and Molding/Trim Removal Kit to remove the front door scuff plate. 2 Remove the front door scuff plate from the B-pillar. 2. Remove the cowl side trim panel by pulling outward to disengage the pin-type retainers. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 9370 Trim Panel: Service and Repair Liftgate Trim Panel Windshield and Molding/Trim Removal Kit Or Equivalent SPECIAL SERVICE TOOL(S) REMOVAL 1. Remove the (A) liftgate handle to liftgate screws and the (B) liftgate handle. 2. Remove the liftgate trim panel screw access plug. 3. Remove the screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 9371 4. Remove the liftgate door trim panel. 1 Use Windshield and Molding/Trim Removal Kit to remove the liftgate door trim panel from the liftgate window opening. 2 Push the liftgate door trim panel toward the top of the liftgate and remove the liftgate trim panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 9372 Trim Panel: Service and Repair Quarter Trim Panel Four Door Special Service Tool(s) SPECIAL SERVICE TOOL(S) REMOVAL 1. If equipped, remove the retractable cargo cover. 2. Remove the liftgate scuff plate. 1 Starting at either end and working along the liftgate scuff plate, use Windshield and Molding/Trim Removal Kit to remove the scuff plate. 2 Remove the liftgate scuff plate. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 9373 3. If equipped, remove the rear power lock switch assembly. - Disconnect the electrical connector. 4. Remove the B-pillar trim panel. 5. Remove the three rear quarter trim panel screws. - Position the carpet aside to gain access to the screws. 6. Remove the rear safety belt anchor nut. 7. Open the rear safety belt guide bolt cover. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 9374 8. Using the special tool, remove the rear safety belt guide bolt. 9. Remove the quarter trim panel. 1 Remove the pin-type retainers. 2 Feed the safety belt webbing through the opening in the quarter trim panel. 3 Remove the quarter trim panel. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 9375 1. Install the quarter trim panel. 1 Feed the safety belt webbing through the opening in the quarter trim panel. 2 Position the quarter trim panel. 3 Install the pin-type retainers. 2. Using the special tool, install the rear safety belt guide bolt. 3. Close the rear safety belt guide bolt cover. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 9376 4. Install the rear safety belt anchor nut. 5. Install the three rear quarter trim panel screws. 6. Install the B-pillar trim panel. 7. Install the liftgate scuff plate. 1 Position the liftgate scuff plate. 2 Start at either end and work along the liftgate scuff plate, pushing it into the floor panel. 8. If equipped, install the retractable cargo cover. Two Door Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 9377 Special Service Tool(s) SPECIAL SERVICE TOOL(S) REMOVAL 1. Remove the windshield side garnish moulding. 2. Remove the front door scuff plate. 3. Remove the front safety belt guide bolt cover. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 9378 4. Using the special tool, remove the front safety belt guide bolt. 5. Using the special tool, remove the front safety belt anchor bolt. 6. If equipped, remove the retractable cargo cover. 7. Remove the liftgate scuff plate. 1 Starting at either end and working along the liftgate scuff plate, use Windshield and Molding/Trim Removal Kit to remove the scuff plate. 2 Remove the liftgate scuff plate. 8. Fold the rear seat into the load floor position. 9. Using the special tool, remove the rear safety belt guide bolt. - Position the rear safety belt guide cover aside. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 9379 10. Using the special tool, remove the rear safety belt anchor bolt. 11. Remove the two rear quarter window latch screws. 12. Remove the coat hook. 1 Remove the screw. 2 Remove the coat hook. 13. Remove the quarter trim panel front screw. - Position the carpet aside to gain access to the screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 9380 14. Remove the three quarter trim panel rear screws. - Position the carpet aside to gain access to the screws. 15. If equipped, remove the rear power lock switch assembly. - Disconnect the electrical connector. 16. Remove the quarter trim panel. 1 Remove the eight pin-type retainers. 2 Feed the safety belt webbing through the opening in the quarter trim panel. 3 Remove the quarter trim panel. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > A-Pillar Trim Panel > Page 9381 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair Door Lock Cylinder: Service and Repair REMOVAL NOTE: - When a lock cylinder is replaced, both door lock cylinders, liftgate lock cylinders and ignition lock cylinder should be replaced as a set. This will eliminate carrying an extra key which will fit only one lock. If a key is to be replaced, the new key code number is stamped on a metal tag attached to the key. - Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. 1. Remove the front door trim panel. 2. Close the window. 3. Remove the watershield. 4. Disconnect the front door latch control cylinder rod from the door lock cylinder lever. 5. Slide the (A) door lock cylinder retainer away from the (B) lock cylinder and remove the cylinder. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics Keyless Entry Key-Pad: Technical Service Bulletins Keyless Entry - Keypad Diagnostics TSB 06-15-8 08/07/06 KEYPAD DIAGNOSTICS - DEALER INSTALLED ACCESSORY FORD: 1998-2006 Taurus 1999-2003 Escort 1999-2006 Mustang 2000-2006 Focus 2002-2005 Thunderbird 2005-2006 Five Hundred, Freestyle 2006 Crown Victoria, Fusion 1998-2006 Expedition, Explorer, F-150, Ranger 1999 F-250 Light Duty 1999-2003 Windstar 1999-2006 F-Super Duty 2000-2005 Excursion 2000-2006 E-Series 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004 F-150 Heritage 2004-2006 Freestar LINCOLN: 1998-2006 Town Car 2000-2006 Lincoln LS 2006 Zephyr 1998-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 1998-2005 Sable 1999-2002 Cougar 2005-2006 Montego 2006 Grand Marquis, Milan 1998-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner ISSUE Some vehicles may experience a concern with the keyless entry keypad. In order to properly diagnose the concern with the keyless entry keypad, it is important to identify whether the keypad is a factory installed style (wired) or a Genuine Ford Accessory (GFA) radio frequency (RF) style keypad. ACTION Use the following Service Procedure to identify GFA RF keypads and provide diagnostic service tips. SERVICE PROCEDURE IDENTIFICATION: 1. Production installed keyless entry keypads are mounted flush with the surface of the vehicle and are wired directly to the module controlling the vehicle's keyless entry system. This style keypad can be diagnosed using the appropriate Workshop Manual (WSM), Section 501-14. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 9392 2. Dealer installed GFA RF keypads are adhesive backed and protrude approximately 1/2" (13 mm) from the surface of the vehicle and there are no specific diagnostics available in the WSM (Figure 1). NOTE THIS RF KEYPAD WAS ALSO US[D IN PRODUCTION ON 2004 F-SUPER DUTY VEHICLES BUILT PRIOR TO 12/3/2003. REFER TO WSM, SECTION 501-14 FOR RF KEYPAD DIAGNOSTICS FOR THESE VEHICLES. GENUINE FORD ACCESSORY KEYPAD DIAGNOSTIC TIPS 1. The keypad operates similarly to a remote keyless entry (RKE) transmitter and is programmed using a similar procedure. Although the RF keypad is not specifically addressed in the WSM, the RKE transmitter programming portion of the WSM, Section 501-14 can be used as a guide NOTE THE 7-8 AND 9-0 BUTTONS ON THE KEYPAD MUST BE PRESSED SIMULTANEOUSLY DURING THE PROCEDURE IN ORDER FOR THE KEYPAD TO BE RECOGNIZED AS AN ADDITIONAL REMOTE TRANSMITTER. Since the GFA RF keypad is essentially another RKE transmitter, the transmitter diagnostic pinpoint tests in the vehicle's WSM can also be referenced even though the buttons serving the lock / unlock functions will differ 2. The GFA RF keypad is serviced as an assembly. The internal battery cannot be replaced separately. 3. If the master code or owner selectable code is lost or forgotten, the GFA RF keypad must be replaced. These codes are not stored in any vehicle module (with the exception of 2004 F-Super Duty vehicles produced prior to 12/3/2003). 4. The GFA RF keypad and all RKE transmitters (the number of transmitters allowable will vary by vehicle) must be reprogrammed together anytime the keypad is replaced, an RKE transmitter is replaced, or the module controlling the keyless entry system on the vehicle (GEM/SJB/VSM/DDM etc.) is replaced. NOTE THERE IS AN EXCEPTION TO TIP 4 FOR VEHICLES EQUIPPED WITH INTEGRATED KEYHEAD TRANSMITTERS (IKTs) (FUSION/MILAN/ZEPHYR). THE GFA RF KEYPADS FOR VEHICLES WITH IKTs MUST BE PROGRAMMED INDEPENDENTLY FROM THE IKTs. TURN THE IGNITION FROM "OFF" TO "RUN" 8 TIMES WITHIN 10 SECONDS, WITH THE 8TH TIME ENDING IN "RUN". THE DOOR LOCKS WILL CYCLE TO CONFIRM ENTERING PROGRAMMING MODE. PRESS THE 7-8 AND 9-0 BUTTON ON THE KEYPAD SIMULTANEOUSLY TO SEND A LOCK SIGNAL. TURN IGNITION TO OFF. THE LOCKS WILL CYCLE AGAIN TO INDICATE THE END OF THE PROGRAMMING MODE. 5. The keypad will normally illuminate for 5 seconds after one or more buttons are pressed, and the illumination will immediately turn off if the 7-8 and 9-0 buttons are pressed simultaneously (lock all doors). The keypad contains an optical sensor and will not illuminate under bright lighting conditions. The keypad may only illuminate briefly in colder temperatures in order to maximize the battery power available to transmit a lock/unlock signal. The temperature at which this occurs will vary depending upon the keypad battery age and condition. Both of these conditions are a normal function of the Power Save Mode and do not indicate a need to replace the keypad. 6. After entering the keypad code, the system may unlock the driver's door, lock it, then unlock it again, and the keypad will not even briefly illuminate. This is the Alert Mode and is an indication that battery power is very low and the keypad must be replaced. 7. The keypad also contains an Anti-scan feature. If the wrong code has been entered 7 times (35 consecutive button presses) the keypad is disabled for one minute and the keypad lamp will flash during this time. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 9393 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14A626 42 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 9394 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 9395 Keyless Entry Key-Pad: Service Precautions CAUTION: Do not operate the radio chassis with a radio speaker disconnected. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 9396 Keyless Entry Key-Pad: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front door trim panel. CAUTION: Do not operate the radio chassis with a radio speaker disconnected. 3. Remove the screws and lift the radio speaker out to gain access to the electrical connector. 4. Disconnect the speaker wiring connector. 5. Disconnect the electrical connector. - Release harness pin-type retainers. 6. Remove the keyless entry keypad and harness. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 9397 1 Remove the clip. 2 Remove the keyless entry keypad and harness. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 10 miles (16 km) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions Keyless Entry Module: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9403 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9404 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9405 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9406 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9407 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9408 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9409 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9410 Keyless Entry Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9411 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9412 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9413 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9414 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9415 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9416 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Page 9417 Keyless Entry Module: Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Page 9418 Keyless Entry Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Page 9419 Keyless Entry Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations Door Latch Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Front Door Actuator Power Door Lock Actuator: Service and Repair Front Door Actuator Heavy Duty Riveter SPECIAL SERVICE TOOLS REMOVAL 1. Remove the front door trim panel. 2. Remove the watershield 3. Remove the power door lock actuator. 1 Disconnect the electrical connector. 2 Drill out the rivet. 3 Disconnect the actuator rod. 4 Remove the actuator. INSTALLATION 1. To install, reverse the removal procedure. - Use Heavy-Duty Riveter to install the actuator rivet. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Front Door Actuator > Page 9426 Power Door Lock Actuator: Service and Repair Rear Door Actuator Heavy Duty Riveter SPECIAL SERVICE TOOLS REMOVAL 1. Remove the rear door trim panel. 2. Remove the rear door watershield. 3. Remove the power door lock actuator. 1 Disconnect the electrical connector. 2 Drill out the rivet. 3 Disconnect the actuator rod. 4 Remove the actuator. INSTALLATION 1. To install, reverse the removal procedure. - Use Heavy-Duty Riveter to install the actuator rivet. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Page 9427 Heavy Duty Riveter Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Locations > Page 9431 Power Door Lock Control Module: Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Locations > Page 9432 Power Door Lock Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Locations > Page 9433 Power Door Lock Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations Power Door Lock Relay: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Page 9437 4 Door W/Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Page 9438 2 Door W/Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Testing and Inspection > Two Door Models Power Door Lock Relay: Testing and Inspection Two Door Models Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Testing and Inspection > Two Door Models > Page 9441 Power Door Lock Relay: Testing and Inspection Four Door Models Driver Door Unlock Relay Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Testing and Inspection > Two Door Models > Page 9442 Door Lock/Unlock Relays Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch 4 Door Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch > Page 9447 Power Door Lock Switch: Diagrams Power Door Lock Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front Power Door Lock Switch: Testing and Inspection Left Front Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 9450 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 9451 Power Door Lock Switch: Testing and Inspection Right Front Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 9452 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Specifications Trunk / Liftgate Lock Cylinder: Specifications Liftgate Lock Cylinder Nuts 6-7 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Specifications > Page 9456 Liftgate Latch Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Specifications > Page 9457 Trunk / Liftgate Lock Cylinder: Service and Repair REMOVAL NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. 1. If equipped, remove the liftgate lock actuator. For additional information, refer to Liftgate Lock Actuator. 2. Remove the liftgate latch remote control. For additional information, refer to Liftgate Latch. 3. Remove the liftgate lock cylinder. 1 Remove the nuts. 2 Remove the liftgate lock cylinder. If equipped, disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Manually close the liftgate window latch to set the latch control rod length. - Make sure the liftgate window latch actuating rod is not preloading the liftgate window latch. It should be clipped in a relaxed state with no slack. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 9466 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 9467 Power Mirror Switch: Testing and Inspection Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 9468 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Premature Clearcoat Cracking Service Tips Paint: Technical Service Bulletins Paint - Premature Clearcoat Cracking Service Tips Article No. 02-17-1 PAINT-PREMATURE CLEARCOAT CRACKING-SERVICE TIPS FORD: 1999-2002 EXPLORER 2000-2002 EXPLORER SPORT TRAC, EXPLORER SPORT MERCURY: 1999-2002 MOUNTAINEER ISSUE Some vehicles may exhibit crowsfoot or premature star cracking primarily on the hood, but could also be on other panels. This is due to high paint film build and acrylic melamine paint technology. ACTION Read this TSB in its entirety BEFORE beginning any repairs. Inspect and repair as outlined in following Service Procedures. SERVICE PROCEDURE 1999-2002 Vehicles-Dark Colors (Code LL Blue, Code UA Black, and Code SU Green only) NOTE READ THIS REPAIR PROCEDURE COMPLETELY. SUBJECT VEHICLES HAVE PAINT THICKNESS ABOVE 5.5 MILS. 1. Check paint film thickness on affected panels. NOTE IF PLASTIC MEDIA BLASTING IS BEING USED, PROCEED TO STEP 4. NOTE TECHNICIAN PERFORMING THE SANDING OPERATION SHOULD WEAR AN APPROVED RESPIRATOR WITH HIGH EFFICIENCY PARTICULATE FILTERS (HEPA). TECHNICIANS SHOULD USE A DUAL ACTION SANDER WITH VACUUM COLLECTION EQUIPMENT. THE VACUUM EQUIPMENT MUST BE EQUIPPED WITH A HEPA FILTER ON THE AIR EXHAUST. OPERATORS ARE CAUTIONED TO FOLLOW MANUFACTURERS GUIDELINES FOR MAINTENANCE OR REPLACEMENT OF THESE FILTERS. 2. Remove all clearcoat and basecoat by sanding down to the E-coat primer with 80 grit-sanding discs on a Dual Action vacuum sander. The E-coat color is Green. 3. Blow off the panel with compressed air to remove loose dust and debris. 4. Wipe the panel with a wax and grease remover. Wipe dry using a clean, lint-free cloth to remove all residue. Keep wiping until the surface is completely dry. 5. Mask off all necessary panels. Tack off the surface. 6. Mix and apply Ford Approved epoxy or self-etching primer to all bare metal areas on the panel. 7. Mix and apply 2.0 mils minimum of Ford Approved primer surfacer following the manufacturers label recommendations and bake at 140°F (60° C) panel temperature per manufacturers recommended baking time. 8. Block sand the affected panels with 600 grit sand paper. 9. Blow off the area with compressed air to remove loose dust and debris. 10. Wipe the panel with a wax and grease remover. Wipe dry using a clean, lint-free cloth to remove all residue. NOTE KEEP WIPING UNTIL THE SURFACE IS COMPLETELY DRY. ANY RESIDUE MAY RESULT CONTAMINATION OF THE COATINGS TO BE APPLIED FOLLOWING THIS STEP. 11. Mix and apply Ford Approved basecoat material following the manufacturers label recommendations and flash time. 12. Mix and apply 2.0 mils minimum of Ford Approved clearcoat and bake at 140°F (60°C) panel temperature per manufacturers recommended baking time. 13. Demask the vehicle as necessary. WARNING TO SAFEGUARD OUR ENVIRONMENT, PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (VOC) OR EXCESS MATERIALS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Premature Clearcoat Cracking Service Tips > Page 9474 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes Paint: Application and ID Paint Codes IDENTIFICATION CODES The Vehicle Identification Number (VIN) is a seventeen-digit combination of letters and numbers. The VIN is stamped on a metal tab riveted on the instrument panel, top upper left of the dash. The VIN number is also found on the Vehicle Certification (VC) label. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 9477 VEHICLE CERTIFICATION LABEL CODES The Vehicle Certification (VC) label contains the manufacturer name, the month and year of manufacture, the certification statement, and the VIN. It also includes Gross Vehicle Weight Ratings (GVWR). The following lists the exterior paint codes: Primary body color codes B2 - Harvest Gold - B4 - Autumn Brown - FL - Medium-Toreador Red - FS - Spruce Green - LD - Medium Wedgewood Blue - LL - Deep Wedgewood Blue - SU - Amazon Green - UA - Ebony - WF - White Pearl, tri-coat (St. Louis build only) - YZ - Oxford White Lower two-tone exterior paint codes: RC - Medium Platinum - BA - Medium Prairie Tan (Mountaineer Appearance Package) - JL - Dark Toreador Red - LD - Medium Wedgewood Blue - ST - Estate Green Tape Stripe Codes Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 9478 - L - Light Prairie Tan (Limited) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 9479 Paint: Application and ID Paint Code Sticker Location VEHICLE CERTIFICATION LABEL REFERENCE The VC label is located on the left-hand front door or door jamb and is in a similar location on trucks. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions Keyless Entry Module: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9486 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9487 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9488 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9489 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9490 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9491 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9492 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9493 Keyless Entry Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9494 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9495 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9496 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9497 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9498 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9499 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Page 9500 Keyless Entry Module: Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Page 9501 Keyless Entry Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Page 9502 Keyless Entry Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Locations > Page 9506 Power Door Lock Control Module: Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Locations > Page 9507 Power Door Lock Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Locations > Page 9508 Power Door Lock Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations Power Door Lock Relay: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 9512 4 Door W/Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 9513 2 Door W/Electronics Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Testing and Inspection > Two Door Models Power Door Lock Relay: Testing and Inspection Two Door Models Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Testing and Inspection > Two Door Models > Page 9516 Power Door Lock Relay: Testing and Inspection Four Door Models Driver Door Unlock Relay Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Testing and Inspection > Two Door Models > Page 9517 Door Lock/Unlock Relays Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams Power Seat Control Module: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Page 9521 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Service Precautions > Technician Safety Information Power Seat Control Module: Technician Safety Information WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Service Precautions > Technician Safety Information > Page 9524 Power Seat Control Module: Vehicle Damage Warnings CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Service Precautions > Page 9525 Power Seat Control Module: Service and Repair REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the seat track assembly. For additional information, refer to Seat-Track, Limited and 6-Way Power. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way Power, Removal and Installation. 3. Remove the Driver Seat Module (DSM). 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the DSM. INSTALLATION CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Service Precautions > Page 9526 1. Install the DSM. 1 Connect the electrical connectors. 2 Position the DSM. 3 Install the screws. 2. Install the seat track. For additional information, refer to Seat-Track, Limited and 6-Way Power. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way Power, Removal and Installation. 3. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. Prove out the air bag system. For additional information, refer to Air Bag Systems. 5. Check the restraint system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Left Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Left > Page 9531 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 9532 Seat Heater Control Module: Service and Repair REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the power front seat track. For additional information refer to Seat-Track, Limited and 6-Way Power. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way Power, Removal and Installation. 3. Disconnect the heated seat module electrical connector. 4. Remove the heated seat module. 1 Release the clip. 2 Remove the heated seat module. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 9533 CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 1. Install the heated seat module. 2. Connect the heated seat module electrical connector. 3. Install the power front seat track. For additional information, refer to Seat-Track, Limited and 6-Way Power. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way Power, Removal and Installation. 4. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Prove out the air bag system. For additional information, refer to Air Bag Systems. 6. Check the restraint system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Specifications Sunroof / Moonroof Motor: Specifications Roof Opening Panel Motor Bolts 5 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Specifications > Page 9539 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Specifications > Page 9540 Sunroof / Moonroof Motor: Service and Repair REMOVAL 1. Remove the overhead console. For additional information, refer to Interior Trim. 2. Remove the motor. 1 Remove the bolts. 2 Disconnect the electrical connector. NOTE: Make sure that the roof opening panel motor is in the closed position before removal. INSTALLATION 1. Connect the roof opening panel motor electrical connector. NOTE: The roof opening panel should be in the closed position. 2. Position the overhead console and connect the electrical connectors. 3. With the motor still removed, bump the switch one time only towards the close or vent open position. 4. Position the roof opening panel motor and install the bolts. 5. Install the overhead console. For additional information, refer to Interior Trim. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Air Deflector Sunroof / Moonroof Windguard: Service and Repair Air Deflector REMOVAL 1. Open the roof opening panel to the fully retracted position. 2. Release the two air deflector arms. 3. Remove the air deflector. 1 Detach the two air deflector retainer clips from the U-frame. 2 Remove the air deflector. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Air Deflector > Page 9548 Sunroof / Moonroof Windguard: Service and Repair Roof Opening Panel Shield REMOVAL 1. Remove the roof opening panel. 2. Remove the water channel. 1 Remove the screws. 2 Remove the water channel. 3. Slide the roof opening panel shield forward halfway. 4. Disengage the roof opening panel shield spring loaded guide feet. 1 Push the roof opening panel shield toward one side of the vehicle. 2 Lift the front portion of the roof opening panel shield upward to disengage the spring loaded guide feet. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Air Deflector > Page 9549 5. Slide the roof opening panel shield forward and release the rear guide feet. INSTALLATION 6. To install, reverse the removal procedure. NOTE: When installing the water channel, make sure that the water channel is seated on the locking clips. The LH water channel screw must be installed first. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair Sunroof / Moonroof Drain: Service and Repair REMOVAL 1. Remove the headliner. 2. From underneath the vehicle, securely attach a new drain hose to the lower end of the old drain hose. 3. Disconnect the drain hose from the roof opening panel assembly. 4. Pull the old drain hose through the body of the vehicle and connect the new hose to the roof opening panel. NOTE: Make sure that the hoses are not kinked. INSTALLATION 1. Install the headliner. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair Sunroof / Moonroof Frame: Service and Repair REMOVAL 1. Remove the headliner. 2. Disconnect the roof opening panel motor electrical connector. 3. Remove the roof opening panel frame. 1 Disconnect the four drain hoses. 2 Remove the fourteen screws. 3 Remove the roof opening panel frame. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams Power Seat Control Module: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Page 9564 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Service Precautions > Technician Safety Information Power Seat Control Module: Technician Safety Information WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Service Precautions > Technician Safety Information > Page 9567 Power Seat Control Module: Vehicle Damage Warnings CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Service Precautions > Page 9568 Power Seat Control Module: Service and Repair REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the seat track assembly. For additional information, refer to Seat-Track, Limited and 6-Way Power. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way Power, Removal and Installation. 3. Remove the Driver Seat Module (DSM). 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the DSM. INSTALLATION CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Service Precautions > Page 9569 1. Install the DSM. 1 Connect the electrical connectors. 2 Position the DSM. 3 Install the screws. 2. Install the seat track. For additional information, refer to Seat-Track, Limited and 6-Way Power. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way Power, Removal and Installation. 3. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 4. Prove out the air bag system. For additional information, refer to Air Bag Systems. 5. Check the restraint system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Left Power Seat Motor: Diagrams Left W/O Memory Seats Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Left > Page 9574 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Left > Page 9575 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Left Power Seat Switch: Diagrams Left Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Left > Page 9580 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service Precautions > Technician Safety Information Power Seat Switch: Technician Safety Information WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service Precautions > Technician Safety Information > Page 9583 Power Seat Switch: Vehicle Damage Warnings CAUTION: - To prevent damage to the side shield, the clips must be depressed in order to release the side shield from the cushion pan. - Use care when disconnecting the seat cushion side shield from the seat cushion frame so the tabs on the seat cushion side shield are not damaged. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Seat Memory Set Switch Power Seat Switch: Testing and Inspection Seat Memory Set Switch Remove the memory set switch. Measure the resistance between the indicated terminals while pressing the requested switches. The resistance should be less than 5 ohms for each switch position. If the resistance is not less than 5 ohms for each switch, replace the switch; otherwise, return to the calling Pinpoint Test. To check the memory set switch LED, connect the positive meter lead to terminal 8 and the negative lead to terminal 9. The meter should indicate greater than 0.3 volts. Reversing the leads, the meter should read OL. If the meter readings are not as indicated above, replace the switch; otherwise, return to the calling Pinpoint Test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Seat Memory Set Switch > Page 9586 Power Seat Switch: Testing and Inspection Seat Regulator Control Switch Remove the seat regulator control switch. Measure the resistance between the indicated terminals while pressing the requested switches. The resistance should be less than 5 ohms for each switch position. If the resistance is not less than 5 ohms for each switch, replace the switch; otherwise, return to the calling Pinpoint Test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Sport Bucket Power Seat Switch: Service and Repair Sport Bucket REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, 3. Remove the lumbar support knob. 4. Remove the rear side shield screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Sport Bucket > Page 9589 5. Release the side shield clips. CAUTION: To prevent damage to the side shield, the clips must be depressed in order to release the side shield from the cushion pan. 6. Unhook the side shield from the seat latch. 7. If equipped, disconnect the heated seat switch electrical connector. 8. Remove the side shield. 1 Disconnect the electrical connector. 2 Remove the side shield. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Sport Bucket > Page 9590 9. Remove the 6-way power seat switch. 1 Remove the screws. 2 Remove the 6-way power seat switch. INSTALLATION WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 1. To install, reverse the removal procedure. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Sport Bucket > Page 9591 Power Seat Switch: Service and Repair Limited REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal and Installation. 3. Disconnect the power seat switch electrical connector. 4. Remove the front seat cushion side shield rear screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Sport Bucket > Page 9592 5. Remove the front seat cushion side shield screws. 6. Disconnect the front seat cushion side shield. CAUTION: Use care when disconnecting the seat cushion side shield from the seat cushion frame so the tabs on the seat cushion side shield are not damaged. 7. Disconnect the lumbar support control switch electrical connector. 8. Disconnect the lumbar support adjusting hoses from the adjusting switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Sport Bucket > Page 9593 9. If equipped, disconnect the heated seat switch electrical connector. 10. Remove the front seat cushion side shield. 11. Remove the 6-way power seat switch. 1 Remove the screws. 2 Remove the 6-way power seat switch. INSTALLATION 1. To install, reverse the removal procedure. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect Technical Service Bulletin # 03S04S1 Date: 060401 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9603 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS will be activated for the additional vehicles by April 3, 2006. FSA VIN LIST ACTIVATED? Yes Available through the website by April 5, 2006. Owner names and addresses will be available for the additional vehicles by April 17, 2006. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE Related damage claims are not approved for this program. ADDITIONAL LABOR TIME This repair will require no additional labor time to complete. Claims submitted with "MT" labor will not be accepted for reimbursement. OWNER REFUNDS ^ Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9604 reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or1 at their option, directly through Ford Motor Company at P.O. Box 6251, Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Refund claims that include other non-covered repairs, or those judged by Ford to be excessive, will not be accepted for reimbursement. ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 03S04 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refund or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires approval from Special Service Support Center. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Please be aware the BB kit will be utilized on approximately 75% of all repairs while the CA kit will only be used on approximately 25% of the repairs. The DOR/COR for this program is 50309. This number identifies parts ordered for this recall through the Special Service Support Center. RECALL PARTS SUPPORT CENTER The Recall Parts Support Center can be contacted via: ^ Phone Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9605 ^ E-mail ^ FAX Please be prepared to provide the following information: ^ Dealer Name and P & A code ^ Contact Name ^ Phone number and E-mail address ^ FSA #: 03804 ^ Vehicle Identification Number (if requested) DEALER PRICE For latest prices1 refer to DOES II. PARTS RETENTION AND RETURN Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information OVERVIEW This procedure involves replacement of certain seat recliner assembly attaching hardware on two different style driver seat assemblies. The driver seat will have either a stamped seat back frame or a tubular seat back frame. These seats can be distinguished from one another by slightly lifting the seat back cover and viewing the corner of the seat back frame itself. See Figures 1 and 2. ^ Tubular seatback frames can be identified by a hole in the lower flange where the recliner mechanism attaches to the seatback frame. See Figure 1. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9606 ^ Stamped seatback frames can be identified by not having the tell-tale hole in the frame that is evident on the tubular seatback frame. See Figure 2. For each type of seat, a different service kit is required. Kits are NOT interchangeable. See Figure 3. ^ Stamped Seatback - The kit consists of: - One (1) UPPER bolt with thread sealer patch (bolt A) - One (1)1-inch spacer (spacer A) ^ Tubular Seatback - The kit consists of: - One (1) UPPER bolt with thread sealer patch (bolt A) - One (1) LOWER bolt without thread sealer patch (bolt B) - One (1) 3/4-inch spacer (spacer B) SERVICE PROCEDURE FOR ALL AFFECTED VEHICLES WARNING: ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIRBAG SUPPLEMENTAL RESTRAINT SYSTEM VEHICLE AND WHEN WORKING NEAR AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF PERSONAL INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. WARNING: TO REDUCE THE RISK OF PERSONAL INJURY, DO NOT USE ANY MEMORY SAVER DEVICES. NOTE: Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9607 If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner system is being serviced, the supplemental restraint system (SRS) must be depowered. 1. NOTE: Only use the method described to distinguish between driver seatback frame types. Trim and accessories may vary from one seat to another of the same frame configuration. Identify the type of seat back frame by slightly lifting the outside rear corner of the seat back cover and viewing the frame itself. Be sure to procure the proper kit based on the type of seat back frame. 2. NOTE: Go to Step 7 if the vehicle is not equipped with side air bags. Record the preset radio stations. 3. Position the driver seat to its full-forward position. 4. Turn the ignition switch from RUN to OFF. 5. Remove the fuse box cover from the left side of the instrument panel near the driver door hinge area and then remove the applicable airbag fuse. Refer to the following chart to determine which fuse must be removed when working on a vehicle with side air bags. 6. Disconnect the battery negative cable and wait one minute. 7. Position the driver seatback to Its full4orward position. 8. CAUTION: Take care not to damage the seatback trim cover during this step. Unhook the seatback trim cover J-clip. See Figure 4. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9608 9. Position the driver seatback to a straight-up position. See Figure 5. 10. Carefully pull the outside of the seatback trim cover up to expose the recliner upper bolt. See Figure 6. 11. Remove and discard the upper bolt. 12. Remove and discard the plastic bushing. See Figure 7. 13. CAUTION: Be sure to use the correct spacer for the application. Refer to Figure 3. ^ Spacer A 1-inch on STAMPED seatback frames. ^ Spacer B 3/4-Inch on TUBULAR seatback frames. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9609 Insert the new spacer from the inboard side of the bolt hole. When Inserted correctly, the spacer should be between the recliner mechanism arm and the seatback frame. See Figure 8. 14. Install the new upper bolt (Bolt A). Tighten the bolt to 45 Nm (33 lb-ft). 15. Carefully install the seatback trim cover over the recliner mechanism arm and into its original position. 16. Position the driver seatback to its full4orward position. 17. Connect the seatback trim cover J-clip. 18. Position the driver seatback to its original position. ^ If the vehicle is equipped with a tubular seatback frame, go to Step 23. ^ If the vehicle is equipped with a stamped seatback frame, continue with the next step. 19. NOTE: If the vehicle is not equipped with side air bags, no further service Is required. Turn the ignition switch from OFF to RUN. 20. Install the airbag fuse and then install the fuse box cover. 21. WARNING: BE SURE THAT NOBODY IS IN THE VEHICLE AND THAT THERE IS NOTHING BLOCKING OR SET IN FRONT OF ANY AIRBAG MODULE WHEN THE BATTERY NEGATIVE CABLE IS CONNECTED. Connect the battery negative cable. 22. Position the driver seat to its original position and program the recorded preset radio stations. THIS COMPLETES SERVICE ON STAMPED SEATBACK FRAMES. FOR TUBULAR SEATBACK FRAMES, PLEASE CONTINUE WITH THE FOLLOWING STEPS. 23. Position the seat cushion side shield aside as follows: ^ Pull off the lumbar support manual adjuster knob, if equipped. ^ Remove two (2) shield attaching screws (three [3] If equipped with power lumbar adjustment). ^ GENTLY unsnap the shield from the seat frame and position the shield out of the way. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9610 24. Remove and discard the lower bolt from the recliner assembly. See Figure 9. 25. Install the new lower bolt (Bolt B) into the recliner assembly. Tighten the bolt to 45 Nm (33 lb-ft). 26. Install the seat cushion side shield as follows: ^ Align and snap the shield into place. ^ Install the two (2) removed screws. ^ Install the lumbar support adjuster knob. 27. NOTE: If the vehicle is not equipped with side air bags, no further service is required. Turn the ignition switch from OFF to RUN. 28. Install the airbag fuse and then install the fuse box cover. 29. WARNING: BE SURE THAT NOBODY IS IN THE VEHICLE AND THAT THERE IS NOTHING BLOCKING OR SET IN FRONT OF ANY AIRBAG MODULE WHEN THE BATTERY NEGATIVE CABLE IS CONNECTED. Connect the battery negative cable. 30. Position the driver seat to its original position and program the recorded preset radio stations. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9611 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9612 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9613 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect Technical Service Bulletin # 03S04S1 Date: 060401 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9619 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS will be activated for the additional vehicles by April 3, 2006. FSA VIN LIST ACTIVATED? Yes Available through the website by April 5, 2006. Owner names and addresses will be available for the additional vehicles by April 17, 2006. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your new vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. RELATED DAMAGE Related damage claims are not approved for this program. ADDITIONAL LABOR TIME This repair will require no additional labor time to complete. Claims submitted with "MT" labor will not be accepted for reimbursement. OWNER REFUNDS ^ Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9620 reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or1 at their option, directly through Ford Motor Company at P.O. Box 6251, Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Refund claims that include other non-covered repairs, or those judged by Ford to be excessive, will not be accepted for reimbursement. ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 03S04 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refund or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires approval from Special Service Support Center. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Please be aware the BB kit will be utilized on approximately 75% of all repairs while the CA kit will only be used on approximately 25% of the repairs. The DOR/COR for this program is 50309. This number identifies parts ordered for this recall through the Special Service Support Center. RECALL PARTS SUPPORT CENTER The Recall Parts Support Center can be contacted via: ^ Phone Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9621 ^ E-mail ^ FAX Please be prepared to provide the following information: ^ Dealer Name and P & A code ^ Contact Name ^ Phone number and E-mail address ^ FSA #: 03804 ^ Vehicle Identification Number (if requested) DEALER PRICE For latest prices1 refer to DOES II. PARTS RETENTION AND RETURN Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information OVERVIEW This procedure involves replacement of certain seat recliner assembly attaching hardware on two different style driver seat assemblies. The driver seat will have either a stamped seat back frame or a tubular seat back frame. These seats can be distinguished from one another by slightly lifting the seat back cover and viewing the corner of the seat back frame itself. See Figures 1 and 2. ^ Tubular seatback frames can be identified by a hole in the lower flange where the recliner mechanism attaches to the seatback frame. See Figure 1. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9622 ^ Stamped seatback frames can be identified by not having the tell-tale hole in the frame that is evident on the tubular seatback frame. See Figure 2. For each type of seat, a different service kit is required. Kits are NOT interchangeable. See Figure 3. ^ Stamped Seatback - The kit consists of: - One (1) UPPER bolt with thread sealer patch (bolt A) - One (1)1-inch spacer (spacer A) ^ Tubular Seatback - The kit consists of: - One (1) UPPER bolt with thread sealer patch (bolt A) - One (1) LOWER bolt without thread sealer patch (bolt B) - One (1) 3/4-inch spacer (spacer B) SERVICE PROCEDURE FOR ALL AFFECTED VEHICLES WARNING: ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIRBAG SUPPLEMENTAL RESTRAINT SYSTEM VEHICLE AND WHEN WORKING NEAR AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF PERSONAL INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. WARNING: TO REDUCE THE RISK OF PERSONAL INJURY, DO NOT USE ANY MEMORY SAVER DEVICES. NOTE: Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9623 If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner system is being serviced, the supplemental restraint system (SRS) must be depowered. 1. NOTE: Only use the method described to distinguish between driver seatback frame types. Trim and accessories may vary from one seat to another of the same frame configuration. Identify the type of seat back frame by slightly lifting the outside rear corner of the seat back cover and viewing the frame itself. Be sure to procure the proper kit based on the type of seat back frame. 2. NOTE: Go to Step 7 if the vehicle is not equipped with side air bags. Record the preset radio stations. 3. Position the driver seat to its full-forward position. 4. Turn the ignition switch from RUN to OFF. 5. Remove the fuse box cover from the left side of the instrument panel near the driver door hinge area and then remove the applicable airbag fuse. Refer to the following chart to determine which fuse must be removed when working on a vehicle with side air bags. 6. Disconnect the battery negative cable and wait one minute. 7. Position the driver seatback to Its full4orward position. 8. CAUTION: Take care not to damage the seatback trim cover during this step. Unhook the seatback trim cover J-clip. See Figure 4. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9624 9. Position the driver seatback to a straight-up position. See Figure 5. 10. Carefully pull the outside of the seatback trim cover up to expose the recliner upper bolt. See Figure 6. 11. Remove and discard the upper bolt. 12. Remove and discard the plastic bushing. See Figure 7. 13. CAUTION: Be sure to use the correct spacer for the application. Refer to Figure 3. ^ Spacer A 1-inch on STAMPED seatback frames. ^ Spacer B 3/4-Inch on TUBULAR seatback frames. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9625 Insert the new spacer from the inboard side of the bolt hole. When Inserted correctly, the spacer should be between the recliner mechanism arm and the seatback frame. See Figure 8. 14. Install the new upper bolt (Bolt A). Tighten the bolt to 45 Nm (33 lb-ft). 15. Carefully install the seatback trim cover over the recliner mechanism arm and into its original position. 16. Position the driver seatback to its full4orward position. 17. Connect the seatback trim cover J-clip. 18. Position the driver seatback to its original position. ^ If the vehicle is equipped with a tubular seatback frame, go to Step 23. ^ If the vehicle is equipped with a stamped seatback frame, continue with the next step. 19. NOTE: If the vehicle is not equipped with side air bags, no further service Is required. Turn the ignition switch from OFF to RUN. 20. Install the airbag fuse and then install the fuse box cover. 21. WARNING: BE SURE THAT NOBODY IS IN THE VEHICLE AND THAT THERE IS NOTHING BLOCKING OR SET IN FRONT OF ANY AIRBAG MODULE WHEN THE BATTERY NEGATIVE CABLE IS CONNECTED. Connect the battery negative cable. 22. Position the driver seat to its original position and program the recorded preset radio stations. THIS COMPLETES SERVICE ON STAMPED SEATBACK FRAMES. FOR TUBULAR SEATBACK FRAMES, PLEASE CONTINUE WITH THE FOLLOWING STEPS. 23. Position the seat cushion side shield aside as follows: ^ Pull off the lumbar support manual adjuster knob, if equipped. ^ Remove two (2) shield attaching screws (three [3] If equipped with power lumbar adjustment). ^ GENTLY unsnap the shield from the seat frame and position the shield out of the way. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9626 24. Remove and discard the lower bolt from the recliner assembly. See Figure 9. 25. Install the new lower bolt (Bolt B) into the recliner assembly. Tighten the bolt to 45 Nm (33 lb-ft). 26. Install the seat cushion side shield as follows: ^ Align and snap the shield into place. ^ Install the two (2) removed screws. ^ Install the lumbar support adjuster knob. 27. NOTE: If the vehicle is not equipped with side air bags, no further service is required. Turn the ignition switch from OFF to RUN. 28. Install the airbag fuse and then install the fuse box cover. 29. WARNING: BE SURE THAT NOBODY IS IN THE VEHICLE AND THAT THERE IS NOTHING BLOCKING OR SET IN FRONT OF ANY AIRBAG MODULE WHEN THE BATTERY NEGATIVE CABLE IS CONNECTED. Connect the battery negative cable. 30. Position the driver seat to its original position and program the recorded preset radio stations. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9627 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9628 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page 9629 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service Precautions > Technician Safety Information Seat Cushion: Technician Safety Information WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service Precautions > Technician Safety Information > Page 9634 Seat Cushion: Vehicle Damage Warnings CAUTION: - The flex mat J-clips must be installed with the openings facing down or the seat cushion will be damaged. - Use care when separating the seat cushion trim cover from the hook and loop strip or the hook and loop strip may be torn from the seat cushion foam. - Any time the seat cushion heating element is removed from the seat cushion foam, the foam must be replaced. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench Seat Cushion: Service and Repair 40% Portion of Rear 60/40 Split Bench DISASSEMBLY 1. Disassemble the rear 40 percent seat. For additional information, refer to Seat-Rear, 60% Portion of 60/40 Split Bench. 2. Remove the rear seat legs. 1. Remove the pivot bolts. 2. Remove the rear seat legs. 3. Unhook the seat cushion trim cover J-clips. 4. Remove the seat cushion trim cover. - Separate the seat cushion trim cover from the hook and loop strip. CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip or the hook and loop strip may be torn from the seat cushion foam. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 9637 5. Remove the seat cushion flex mat. 1. Unhook the rear flex mat J-clip. 2. Unhook the front flex mat J-clip. 3. Remove the seat cushion flex mat. NOTE: Use the brackets on the seat cushion frame to obtain the necessary leverage to unhook the rear flex mat J-clip. ASSEMBLY 1. Install the seat cushion flex mat. 1. Position the seat cushion flex mat. 2. Hook the front flex mat J-clip. 3. Hook the rear flex mat J-clip. CAUTION: The flex mat J-clips must be installed with the openings facing down or the seat cushion will be damaged. NOTE: Use the brackets on the seat cushion frame to obtain the necessary leverage to hook the rear flex mat J-clip. 2. Position the seat cushion trim cover on the seat cushion hook and loop strips. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 9638 3. Hook the seat cushion trim cover J-clips. 4. Install the rear seat riser pivot bolts. 1. Position the rear seat legs. 2. Install the rear seat riser pivot bolts. 5. Assemble the rear 40 percent seat. For additional information, refer to Seat-Rear, 60% Portion of 60/40 Split Bench. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 9639 Seat Cushion: Service and Repair 60% Portion of Front 60/40 Split Bench DISASSEMBLY 1. Disassemble the seat. For additional information, refer to Seat-60% Portion of Front 60/40 Split Bench. 2. Unhook the seat cushion trim cover J-clips. 3. Remove the seat cushion frame from the seat cushion foam. 4. Invert the seat cushion trim cover. 5. Remove the seat cushion trim cover. Separate the seat cushion trim cover from the hook and loop strip. CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip or the hook and loop strip may be torn from the seat cushion foam. ASSEMBLY 1. To assemble, reverse the disassembly procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 9640 Seat Cushion: Service and Repair 60% Portion of Rear 60/40 Split Bench DISASSEMBLY 1. Disassemble the 60 percent rear seat. For additional information, refer to Seat-Rear, 60% Portion of 60/40 Split Bench. 2. Remove the seat cushion legs. 1. Remove the pivot bolts. 2. Remove the seat cushion legs. 3. Remove the seat cushion frame from the seat cushion foam. 1. Unhook the seat cushion trim cover J-clips. 2. Remove the seat cushion frame from the seat cushion foam. 4. Invert the seat cushion trim cover. 5. Remove the seat cushion trim cover. - Separate the seat cushion trim cover from the hook and loop strip. CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip or the hook and loop strip may be torn from the seat cushion foam. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 9641 6. Remove the seat cushion flex mats. 1. Unhook the rear flex mat J-clips. 2. Unhook the front flex mat J-clips. 3. Remove the seat cushion flex mats. NOTE: Use the brackets on the seat cushion frame to obtain the necessary leverage to unhook the rear flex mat J-clip. ASSEMBLY 1. Install the seat cushion flex mats. 1. Position the seat cushion flex mats. 2. Hook the front flex mat J-clips. 3. Hook the rear flex mat J-clips. CAUTION: The flex mat J-clips must be installed with the openings facing down or the seat cushion foam will be damaged. NOTE: Use the brackets on the seat cushion frame to obtain the necessary leverage to hook the rear flex mat clip. 2. Position the seat cushion trim cover on the seat cushion hook and loop strips. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 9642 3. Install the seat cushion frame into the seat cushion foam. 1. Position the seat cushion frame. 2. Hook the seat cushion trim cover J-clips. 4. Install the seat cushion legs. 1. Position the seat cushion legs. 2. Install the rear seat riser pivot bolts. 5. Assemble the 60 percent rear seat. For additional information, refer to Seat-Rear, 60% Portion of 60/40 Split Bench. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 9643 Seat Cushion: Service and Repair Front Bucket 6-Way Power, Except Limited DISASSEMBLY WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. - Before disconnecting the battery, raise the seat to the highest position, then move and tilt the seat to its most forward position. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Disassemble the 6-way power front bucket seat. For additional information, refer to Seat-Front Bucket, 6-Way Power, Except limited. NOTE : Be sure to read and follow all air bag warnings in Seat-Front Bucket, 6Way Power, Except Limited, Disassembly and Assembly. 3. Disconnect the seat cushion trim cover J-clips. 4. If equipped, disconnect the seat cushion heating element electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 9644 5. Remove the seat cushion frame from the seat cushion foam. 6. Invert the seat cushion trim cover. 7. Remove the swing rods. 1 Remove and discard the hog rings. 2 Remove the swing rods. 8. Remove the seat cushion trim cover. CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip or the hook and loop strip may be torn from the seat cushion foam. 9. If equipped, and if necessary, remove the seat cushion heating element from the seat cushion foam. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 9645 CAUTION: Any time the seat cushion heating element is removed from the seat cushion foam, the foam must be replaced. 10. Remove the wire harness from the scat cushion frame. ASSEMBLY 1. Install the wire harness. 2. If equipped, and if necessary, install the seat cushion heating element. 3. Position the seat cushion trim cover. NOTE: When installing a new seat cushion trim cover, it may be necessary to cut a hole for the front seat back pad adjusting cable, backrest heating element electrical lead, and the side air bag wiring harness. Use the old seat cushion trim cover as a guide for the location of the hole. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 9646 4. Install the seat cushion swing rods. 1 Position the swing rods. NOTE: Make sure the ends of the swing rods are positioned beneath the listing wires at the rear of the seat cushion foam. 2 Install the hog rings. 5. Invert the seat cushion trim cover. 6. Connect the seat cushion trim cover J-clips. 7. Assemble the 6-way power front bucket seat. For additional information, refer to Seat-Front Bucket, 6-Way Power, Except Limited. NOTE: Be sure to read and follow all air bag warnings in Seat-Front Bucket, 6-Way Power, Except Limited, Disassembly and Assembly. 8. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 9. Prove out the air bag system. For additional information, refer to Air Bag Systems. 10. Check the restraint system for proper operation. Limited DISASSEMBLY WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 9647 - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. - Before disconnecting the battery, raise the seat to the highest position, then move and tilt the seat to its most forward position. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Disassemble the seat. For additional information, refer to Seat-Front Bucket, Limited. NOTE: Be sure to read and follow all air bag warnings in Seat-Front Bucket, Limited, Disassembly and Assembly. 3. Disconnect the seat backrest recliner actuator. 1 Remove the screws. 2 Disconnect the seat backrest recliner actuator. 4. If equipped, disconnect the seat cushion heating element electrical connector. 5. Remove the seat cushion frame from the seat cushion foam. 1 Unhook the seat cushion trim cover J-clips. 2 Remove the seat cushion frame from the seat cushion foam. 6. Invert the seat cushion trim cover. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 9648 7. Remove and discard the hog rings. 1 Fold back the seat cushion trim cover to expose the hog rings. 2 Remove and discard the hog rings. NOTE: The hog rings along the front of the seat are shown, the hog rings along either side are similar. 8. If equipped, and if necessary, remove the seat cushion heating element from the seat cushion foam. CAUTION: Any time the seat cushion heating element is removed from the seat cushion foam, the foam must be replaced. NOTE: Sport bucket seat shown; Limited seat similar. 9. Disconnect the heated seat module electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 9649 10. Remove the heated seat module. 1 Release the clip. 2 Remove the heated seat module. 11. Remove the driver seat module (DSM). 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the DSM. 12. Disconnect the lumbar support adjusting pump electrical connector. 13. Remove the power seat wiring harness. 1 Disconnect the pin-type retainers. 2 Remove the power seat wiring harness. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 9650 14. Remove the flexilator. 1 Remove the flexilator springs. 2 Remove the flexilator. 15. Remove the lumbar support adjusting pump. 1 Remove the bolt. 2 Remove the lumbar support adjusting pump. 16. Remove the seat backrest recliner roll pins and remove the seat backrest recliners. 17. Disconnect the seat backrest recliners from the seat backrest recliner actuator. 1 Disconnect the seat backrest recliner actuator cable housings from the seat backrest recliners. 2 Unhook the seat backrest recliner actuator cables from the seat backrest recliners. ASSEMBLY Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 9651 1. Connect the seat backrest recliners to the seat backrest recliner actuator. 1 Hook the seat backrest recliner actuator cables to the seat backrest recliners. 2 Connect the seat backrest recliner actuator cable housings to the seat backrest recliners. 2. Install the seat backrest recliner roll pins. 3. Install the lumbar Support adjusting pump. 1 Position the lumbar support adjusting pump. 2 Install the bolt. 4. Install the flexilator. 1 Position the flexilator. 2 Install the flexilator springs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 9652 5. Install the power seat wiring harness. 1 Position the power seat wiring harness. 2 Install the pin-type retainers. 6. Connect the lumbar support adjusting pump electrical connector. 7. Install the DSM. 1 Connect the electrical connectors. 2 Position the DSM. 3 Install the screws. 8. Install the hog rings. 1 Fold back the seat cushion trim cover to the hog ring installation position. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 9653 2 Install the hog rings. NOTE: The hog rings along the front of the seat are shown; the hog rings along either side are similar. 9. Invert the seat cushion trim cover. 10. Install the seat cushion frame. 1 Position the seat cushion frame. 2 Hook the seat cushion trim cover J-clips. 11. If equipped, connect the seat cushion heating element electrical connector. 12. Connect the seat backrest recliner actuator. 1 Connect the seat backrest recliner actuator. 2 Install the screws. Tighten until the screws are fully seated. 13. Assemble the seat. For additional information, refer to Seat-Front Bucket, Limited. NOTE: Be sure to read and follow all air bag warnings in Seat-Front Bucket, Limited, Disassembly and Assembly. 14. Reactivate the supplemental restraint system. For additional information, refer to Section Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 15. Prove out the air bag system. For additional information, refer to Air Bag Systems. 16. Check the restraint system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 9654 Manual DISASSEMBLY 1. Disassemble the manual front bucket seat. For additional information, refer to Seat-Front Bucket, Manual. 2. Disconnect the seat cushion trim cover J-clips. 3. Remove the seat cushion trim cover. - Disconnect the seat trim cover from the hook and loop strips. CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip or the hook and loop strip may be torn from the seat cushion foam. 4. Remove the seat cushion. - Disconnect the front and rear J-clips. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 9655 5. Remove the flexilator. 1. Remove the flexilator to frame springs. 2. Disengage the spring clip. 3. Disengage the flexilator hooks from the seat frame. 4. Remove the flexilator. ASSEMBLY 1. Install the flexilator. 1. Position the flexilator. 2. Install the flexilator hooks to the seat frame. 3. Hook the spring clip. 4. Install the flexilator to frame springs. 2. Position the seat cushion trim cover on the seat cushion hook and loop strips. 3. Connect the seat cushion trim cover J-clips. 4. Assemble the manual front bucket seat. For additional information, refer to Seat-Front Bucket, Manual. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 9656 Seat Cushion: Service and Repair Rear 50/50 Split Bench DISASSEMBLY 1. Remove the pivot legs. 1. Remove the bolts. 2. Remove the pivot legs. 2. Remove the seat cushion trim cover. - Disconnect the pin-type retainers. 3. Remove the seat cushion foam from the seat cushion frame. ASSEMBLY Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40% Portion of Rear 60/40 Split Bench > Page 9657 1. To assemble, reverse the disassembly procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Left Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Left > Page 9662 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Page 9663 Seat Heater Control Module: Service and Repair REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the power front seat track. For additional information refer to Seat-Track, Limited and 6-Way Power. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way Power, Removal and Installation. 3. Disconnect the heated seat module electrical connector. 4. Remove the heated seat module. 1 Release the clip. 2 Remove the heated seat module. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Page 9664 CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 1. Install the heated seat module. 2. Connect the heated seat module electrical connector. 3. Install the power front seat track. For additional information, refer to Seat-Track, Limited and 6-Way Power. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way Power, Removal and Installation. 4. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 5. Prove out the air bag system. For additional information, refer to Air Bag Systems. 6. Check the restraint system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Left Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Left > Page 9669 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Sport Bucket Seat Heater Switch: Service and Repair Sport Bucket REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal and Installation. 3. Remove the lumbar support knob. 4. Remove the rear side shield screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Sport Bucket > Page 9672 5. Release the side shield clips. 6. Disconnect the heated seat switch electrical connector. 7. Remove the heated seat switch. INSTALLATION 1. To install, reverse the removal procedure. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Sport Bucket > Page 9673 Seat Heater Switch: Service and Repair Limited REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat Systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal and Installation. 3. Disconnect the power seat switch electrical connector. 4. Remove the front seat cushion side shield rear screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Sport Bucket > Page 9674 5. Remove the front seat cushion side shield screws. 6. Disconnect the front seat cushion side shield. CAUTION: Use care when disconnecting the seat cushion side shield from the seat cushion frame so the tabs on the seat cushion side shield are not damaged. 7. Disconnect the lumbar support control switch electrical connector. 8. Disconnect the lumbar support adjusting hoses from the adjusting switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Sport Bucket > Page 9675 9. Disconnect the heated seat switch electrical connector. 10. Remove the front seat cushion side shield. 11. Remove the heated seat switch. INSTALLATION 1. To install, reverse the removal procedure. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Front Manual Seat Track: Service and Repair Front Manual REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket, Removal and Installation. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket. 3. Place the front seat upside-down on a clean workbench. 4. Remove the safety belt buckle slide bar. 1 Remove the nut. 2 Remove the bolt. 3 Remove the safety belt buckle slide bar. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Front Manual > Page 9680 5. Remove the seat track to seat cushion front bolts. 6. Remove the front seat track. 1 Remove the seat track to seat cushion rear bolts. 2 Remove the front seat track. INSTALLATION 1. Install the front seat track front bolts. 1 Position the front seat track. 2 Install the inboard bolt. 3 Install the outboard bolt. 2. Install the front seat track rear bolts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Front Manual > Page 9681 1 Install the inboard bolt. 2 Install the outboard bolt. 3. Install the safety belt buckle slide bar. 1 Position the safety belt buckle slide bar. 2 Install the nut. 3 Install the bolt. 4. Install the front seat. For additional information, refer to Seat-Front Bucket. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal and Installation. 5. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 6. Prove out the air bag system. For additional information, refer to Air Bag Systems. 7. Check the restraint system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Front Manual > Page 9682 Seat Track: Service and Repair Limited and 6-Way Power REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. NOTE: - LHD seats shown, RHD seat similar. - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal and Installation. 3. Place the seat on a clean workbench. 4. Remove the safety belt buckle slide bar. 1 Remove the nut. 2 Remove the bolt. 3 Remove the safety belt buckle slide bar. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Front Manual > Page 9683 5. Disconnect the seat track wiring hamess electrical connectors. - If equipped, disconnect the memory seat module electrical connectors. - Disconnect the seat track motor electrical connectors. 6. Remove the seat track. 1 Remove the bolts. 2 Remove the seat track. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When installing the power seat track, start at the corner with the round hole and work around the seat base in a horseshoe pattern. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Front Manual > Page 9684 4. Check the restraint system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 SOHC VIN K SFI (2001)) 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 9691 OASIS CODES: 201000, 201200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch 4 Door Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Master Window/Door Lock Control Switch > Page 9696 Power Door Lock Switch: Diagrams Power Door Lock Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front Power Door Lock Switch: Testing and Inspection Left Front Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 9699 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 9700 Power Door Lock Switch: Testing and Inspection Right Front Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 9701 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 9705 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 9706 Power Mirror Switch: Testing and Inspection Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 9707 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Left Power Seat Switch: Diagrams Left Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Left > Page 9712 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service Precautions > Technician Safety Information Power Seat Switch: Technician Safety Information WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service Precautions > Technician Safety Information > Page 9715 Power Seat Switch: Vehicle Damage Warnings CAUTION: - To prevent damage to the side shield, the clips must be depressed in order to release the side shield from the cushion pan. - Use care when disconnecting the seat cushion side shield from the seat cushion frame so the tabs on the seat cushion side shield are not damaged. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Memory Set Switch Power Seat Switch: Testing and Inspection Seat Memory Set Switch Remove the memory set switch. Measure the resistance between the indicated terminals while pressing the requested switches. The resistance should be less than 5 ohms for each switch position. If the resistance is not less than 5 ohms for each switch, replace the switch; otherwise, return to the calling Pinpoint Test. To check the memory set switch LED, connect the positive meter lead to terminal 8 and the negative lead to terminal 9. The meter should indicate greater than 0.3 volts. Reversing the leads, the meter should read OL. If the meter readings are not as indicated above, replace the switch; otherwise, return to the calling Pinpoint Test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Seat Memory Set Switch > Page 9718 Power Seat Switch: Testing and Inspection Seat Regulator Control Switch Remove the seat regulator control switch. Measure the resistance between the indicated terminals while pressing the requested switches. The resistance should be less than 5 ohms for each switch position. If the resistance is not less than 5 ohms for each switch, replace the switch; otherwise, return to the calling Pinpoint Test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Sport Bucket Power Seat Switch: Service and Repair Sport Bucket REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, 3. Remove the lumbar support knob. 4. Remove the rear side shield screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Sport Bucket > Page 9721 5. Release the side shield clips. CAUTION: To prevent damage to the side shield, the clips must be depressed in order to release the side shield from the cushion pan. 6. Unhook the side shield from the seat latch. 7. If equipped, disconnect the heated seat switch electrical connector. 8. Remove the side shield. 1 Disconnect the electrical connector. 2 Remove the side shield. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Sport Bucket > Page 9722 9. Remove the 6-way power seat switch. 1 Remove the screws. 2 Remove the 6-way power seat switch. INSTALLATION WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 1. To install, reverse the removal procedure. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Sport Bucket > Page 9723 Power Seat Switch: Service and Repair Limited REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal and Installation. 3. Disconnect the power seat switch electrical connector. 4. Remove the front seat cushion side shield rear screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Sport Bucket > Page 9724 5. Remove the front seat cushion side shield screws. 6. Disconnect the front seat cushion side shield. CAUTION: Use care when disconnecting the seat cushion side shield from the seat cushion frame so the tabs on the seat cushion side shield are not damaged. 7. Disconnect the lumbar support control switch electrical connector. 8. Disconnect the lumbar support adjusting hoses from the adjusting switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Sport Bucket > Page 9725 9. If equipped, disconnect the heated seat switch electrical connector. 10. Remove the front seat cushion side shield. 11. Remove the 6-way power seat switch. 1 Remove the screws. 2 Remove the 6-way power seat switch. INSTALLATION 1. To install, reverse the removal procedure. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Left Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Left > Page 9730 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Sport Bucket Seat Heater Switch: Service and Repair Sport Bucket REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal and Installation. 3. Remove the lumbar support knob. 4. Remove the rear side shield screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Sport Bucket > Page 9733 5. Release the side shield clips. 6. Disconnect the heated seat switch electrical connector. 7. Remove the heated seat switch. INSTALLATION 1. To install, reverse the removal procedure. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Sport Bucket > Page 9734 Seat Heater Switch: Service and Repair Limited REMOVAL WARNING: - ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. - AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD. - THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: - If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. - Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. - Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. - Diagnostics may be performed on seat Systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. - After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket. NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal and Installation. 3. Disconnect the power seat switch electrical connector. 4. Remove the front seat cushion side shield rear screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Sport Bucket > Page 9735 5. Remove the front seat cushion side shield screws. 6. Disconnect the front seat cushion side shield. CAUTION: Use care when disconnecting the seat cushion side shield from the seat cushion frame so the tabs on the seat cushion side shield are not damaged. 7. Disconnect the lumbar support control switch electrical connector. 8. Disconnect the lumbar support adjusting hoses from the adjusting switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Sport Bucket > Page 9736 9. Disconnect the heated seat switch electrical connector. 10. Remove the front seat cushion side shield. 11. Remove the heated seat switch. INSTALLATION 1. To install, reverse the removal procedure. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Page 9746 Trunk / Liftgate Switch: Testing and Inspection Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Page 9747 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and Operation Sound Proofing / Insulation: Description and Operation INSULATION Insulation is installed: - under the hood. - above and below the instrument panel. - at the A-pillar lower trim panel. - over the front and rear tunnel. - over the front and rear floor pans. - inside the B-pillar. - inside the C-pillar. - inside the D-pillar (Explorer Sport). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL PANEL GRILLE Removal and Installation 1. Disconnect the driver side windshield washer hose from inside the engine compartment. 2. Remove the windshield wiper pivot arms. 1. Slide the clip so the windshield wiper pivot arm will clear the windshield wiper pivot shaft. 2. Pull the windshield wiper pivot arm from the windshield wiper pivot shaft. 3. Remove the cowl grille screw. 4. Remove the driver side cowl grille. - Pull up on the cowl grille to disengage the clips. 5. Remove the passenger side cowl grille. - Pull up on the cowl grille to disengage the clips and disconnect the washer hose. 6. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Brake Switch (Cruise Control): Recalls Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9769 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9770 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9771 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9772 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9773 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9774 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9775 Attachment III - Technical Information Table of Contents Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9776 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9777 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9778 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9779 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9780 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9781 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9782 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9783 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9784 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9785 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9786 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9787 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9788 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9789 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9790 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9791 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9792 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9793 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9794 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 9799 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Brake Switch (Cruise Control): All Technical Service Bulletins Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9809 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9810 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9811 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9812 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9813 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9814 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9815 Attachment III - Technical Information Table of Contents Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9816 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9817 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9818 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9819 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9820 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9821 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9822 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9823 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9824 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9825 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9826 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9827 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9828 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9829 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9830 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9831 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9832 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9833 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9834 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): All Technical Service Bulletins Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 9839 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 9840 Brake Switch (Cruise Control): Specifications Deactivator Switch 15-20 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Technician Safety Information Brake Switch (Cruise Control): Technician Safety Information WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Technician Safety Information > Page 9843 Brake Switch (Cruise Control): Vehicle Damage Warnings 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. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Page 9844 Brake Switch (Cruise Control): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the deactivator switch electrical connector. 3. Remove the deactivator switch. WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES 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: 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. INSTALLATION 1. To install, reverse the removal procedure. NOTE ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. ^ After the deactivator switch is installed, it is necessary to bleed the brake system; refer to Brakes. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating Technical Service Bulletin # 09S09 Date: 091013 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9853 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on October 13, 2009. NOTE: This recall pertains to certain vehicles that have a factory installed speed control deactivation switch only. Ford offered a Genuine Accessory Speed Control kit that utilized a production steering wheel identical to the factory-installed system. The Ford accessory kit does not use a master cylinder mounted deactivation switch and, as a result, vehicles with this kit are not included in this recall. If a customer inquires about Safety Recall 09509, and the VIN of their vehicle is not listed in OASIS under 09509, the vehicle is not involved in the program. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by October 15, 2009. Owner names and addresses will be available by December 18, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9854 RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Ford Motor Company is offering a refund for owner paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ Refunds will only be provided for the cost associated with repairs due to a leaking speed control deactivation switch. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 09S09 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. ^ Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim. If a repair is performed on the same visit, the repair and refunds should be submitted on separate repair lines. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. ^ Claiming information for Electrical Grease II for servicing both the speed control servo and SCDS adapter jumper harness connector - applies to Labor Operation 09509G or 09S09H. (Submit on same repair line as repair.) - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $6.30 ^ Claiming information for Electrical Grease II for servicing SCDS adapter jumper harness connector only - applies to Labor Operation 09509D, 09509F or 09509J (Submit on same repair line as repair.) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9855 - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $0.50 Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9856 PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this safety recall is 50409. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Affected speed control deactivation switches and related damage parts are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9857 TABLE OF CONTENTS OVERVIEW This Safety Recall involves an inspection of the Speed Control Deactivation Switch (SCDS) harness connector for the presence of brake fluid contamination. If no brake fluid is present, install the universal fused jumper harness. If brake fluid is present, replace the SCDS and inspect the speed control servo harness connector for heat damage. See Flow Chart # 2. In addition, for 1999 through 2003 Windstar vehicles, the repair includes an inspection of the Anti-lock Brake System (ABS) connectors. See Flow Chart # 2. If a related damage condition is found that you believe to be caused by a leaking SCDS, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. REPAIR FLOW CHARTS Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9858 Flow Chart # 1 shows the repair procedure for all affected vehicles except 1999 through 2003 Windstar vehicles. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9859 Flow Chart # 2 shows the repair procedure for 1999 through 2003 Windstar vehicles. SCDS Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9860 The Speed Control Deactivation Switch (SCDS) involved in Safety Recall 09S09 and the revised SCDS are illustrated (See Figure 1). Note that the revised SCDS has a different electrical connector An adapter jumper harness (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS SCDS Location In most vehicles involved in this recall, the SCDS is located on the master cylinder. In 1992-1993 E-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail under the driver's seat. In 1993 F-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail below the master cylinder To verify, just follow the metal brake lines from the master cylinder until the switch is found On F-53 Motorhome vehicles, if the SCDS is not located on the master cylinder, it maybe located in a brake line junction block approximately 457 mm (18 in) below the master cylinder It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. SCDS INSPECTION PROCEDURE NOTE: For E-Series vehicles, there is a possibility that the vehicle was manufactured without a SCDS If unable to locate a SCDS after checking on all the brake lines, no further action is required, release the vehicle NOTE: On 1992-1993 E-Series and 1993 F-Series vehicles, it may be necessary to lift the vehicle to gain access to the SCDS On Windstar vehicles, the air cleaner housing must be separated in the middle to gain access to the SCDS Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9861 1. Disconnect the harness connector from the SCDS (See Figure 2) 2. Inspect the harness connector for the presence of brake fluid. ^ If there is no evidence of brake fluid on the connector, install Universal Fused Jumper Harness (UFJH). ^ If there is evidence of brake fluid on the connector, replace SCDS. UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION 1. Connect the Universal Fused Jumper Harness (UFJH) to the SCDS and the vehicle harness. 2. Secure the UFJH to the existing harness with tie straps making sure the fuse holders are positioned vertically with the fuse holder cap facing upward Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9862 Wrap the tie straps underneath then over the top of the existing harness and verify proper fuse holder orientation (See Figure 3). 3. No further action is required release the vehicle. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and if necessary fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS (See Figure 4). NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed 3. Remove the old SCDS. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft). 5. Check the brake fluid level at the master cylinder fill to maximum fluid level and install the brake fluid reservoir cap. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9863 6. Before installing the adapter jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II (XG-15-A) (See Figure 5). 7. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the adapter jumper harness to a nearby component such as the speed control cable or another wire harness. ^ If the vehicle has a speed control servo, proceed with speed control servo inspection. ^ If the vehicle is a 1999-2003 Windstar that does not have speed control, proceed with ABS inspection. ^ If none of the above apply, no further action is required, release the vehicle. SPEED CONTROL SERVO INSPECTION 1. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage (See Figure 6) ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector) proceed to step 2 for further instructions. ^ If heat damage is found proceed as follows: - 1999-2003 Windstar complete ABS inspection before calling the Special Service Support Center for further instructions. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9864 - All other vehicles call the Special Service Support Center for further instructions. 2. With the speed control servo disconnected use shop air to blow out any trace of brake fluid from the speed control servo harness electrical connector and the servo module. Do not use any type of solvent to clean the connectors. 3. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II (XG-15-A) across the entire width and length of the servo vehicle harness connector (See Figure 7). NOTICE: Be sure to apply an adequate amount of grease to the vehicle harness connector only DO NOT apply the grease directly to the connector of the servo module. 4. Reconnect the harness to the servo module. 5. If the vehicle is a 1999-2OO3 Windstar proceed to ABS inspection. Otherwise no further action is required, release the vehicle. ANTI-LOCK BRAKE SYSTEM (ABS) INSPECTION NOTE: This inspection applies to 1999 through 2003 Windstar vehicles only. 1. Lift vehicle and remove ABS cover. 2. Disconnect ABS module. Inspect the ABS harness and module connectors for the presence of brake fluid. 3. If brake fluid is present use shop air to blow out any trace of brake fluid from the harness connector and module. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9865 4. Inspect the ABS harness and module connectors for corrosion and/or heat damage (See Figure 8). 5. If evidence of corrosion and/or heat damage is found in either the ABS harness or module connector call the Special Service Support Center for further instructions. 6. If there is no evidence of corrosion and/or heat damage reconnect the ABS harness to the ABS module. 7. Is the speed control servo heat damaged? ^ If the speed control servo is heat damaged call the Special Service Support Center for further instructions. ^ If the speed control servo is not heat damaged no further action is required release the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9866 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9867 Owner Letter Owner Letter not available at this time. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating Technical Service Bulletin # 09S09 Date: 091013 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9873 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on October 13, 2009. NOTE: This recall pertains to certain vehicles that have a factory installed speed control deactivation switch only. Ford offered a Genuine Accessory Speed Control kit that utilized a production steering wheel identical to the factory-installed system. The Ford accessory kit does not use a master cylinder mounted deactivation switch and, as a result, vehicles with this kit are not included in this recall. If a customer inquires about Safety Recall 09509, and the VIN of their vehicle is not listed in OASIS under 09509, the vehicle is not involved in the program. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by October 15, 2009. Owner names and addresses will be available by December 18, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9874 RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Ford Motor Company is offering a refund for owner paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ Refunds will only be provided for the cost associated with repairs due to a leaking speed control deactivation switch. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 09S09 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. ^ Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim. If a repair is performed on the same visit, the repair and refunds should be submitted on separate repair lines. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. ^ Claiming information for Electrical Grease II for servicing both the speed control servo and SCDS adapter jumper harness connector - applies to Labor Operation 09509G or 09S09H. (Submit on same repair line as repair.) - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $6.30 ^ Claiming information for Electrical Grease II for servicing SCDS adapter jumper harness connector only - applies to Labor Operation 09509D, 09509F or 09509J (Submit on same repair line as repair.) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9875 - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $0.50 Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9876 PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this safety recall is 50409. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Affected speed control deactivation switches and related damage parts are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9877 TABLE OF CONTENTS OVERVIEW This Safety Recall involves an inspection of the Speed Control Deactivation Switch (SCDS) harness connector for the presence of brake fluid contamination. If no brake fluid is present, install the universal fused jumper harness. If brake fluid is present, replace the SCDS and inspect the speed control servo harness connector for heat damage. See Flow Chart # 2. In addition, for 1999 through 2003 Windstar vehicles, the repair includes an inspection of the Anti-lock Brake System (ABS) connectors. See Flow Chart # 2. If a related damage condition is found that you believe to be caused by a leaking SCDS, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. REPAIR FLOW CHARTS Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9878 Flow Chart # 1 shows the repair procedure for all affected vehicles except 1999 through 2003 Windstar vehicles. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9879 Flow Chart # 2 shows the repair procedure for 1999 through 2003 Windstar vehicles. SCDS Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9880 The Speed Control Deactivation Switch (SCDS) involved in Safety Recall 09S09 and the revised SCDS are illustrated (See Figure 1). Note that the revised SCDS has a different electrical connector An adapter jumper harness (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS SCDS Location In most vehicles involved in this recall, the SCDS is located on the master cylinder. In 1992-1993 E-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail under the driver's seat. In 1993 F-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail below the master cylinder To verify, just follow the metal brake lines from the master cylinder until the switch is found On F-53 Motorhome vehicles, if the SCDS is not located on the master cylinder, it maybe located in a brake line junction block approximately 457 mm (18 in) below the master cylinder It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. SCDS INSPECTION PROCEDURE NOTE: For E-Series vehicles, there is a possibility that the vehicle was manufactured without a SCDS If unable to locate a SCDS after checking on all the brake lines, no further action is required, release the vehicle NOTE: On 1992-1993 E-Series and 1993 F-Series vehicles, it may be necessary to lift the vehicle to gain access to the SCDS On Windstar vehicles, the air cleaner housing must be separated in the middle to gain access to the SCDS Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9881 1. Disconnect the harness connector from the SCDS (See Figure 2) 2. Inspect the harness connector for the presence of brake fluid. ^ If there is no evidence of brake fluid on the connector, install Universal Fused Jumper Harness (UFJH). ^ If there is evidence of brake fluid on the connector, replace SCDS. UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION 1. Connect the Universal Fused Jumper Harness (UFJH) to the SCDS and the vehicle harness. 2. Secure the UFJH to the existing harness with tie straps making sure the fuse holders are positioned vertically with the fuse holder cap facing upward Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9882 Wrap the tie straps underneath then over the top of the existing harness and verify proper fuse holder orientation (See Figure 3). 3. No further action is required release the vehicle. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and if necessary fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS (See Figure 4). NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed 3. Remove the old SCDS. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft). 5. Check the brake fluid level at the master cylinder fill to maximum fluid level and install the brake fluid reservoir cap. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9883 6. Before installing the adapter jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II (XG-15-A) (See Figure 5). 7. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the adapter jumper harness to a nearby component such as the speed control cable or another wire harness. ^ If the vehicle has a speed control servo, proceed with speed control servo inspection. ^ If the vehicle is a 1999-2003 Windstar that does not have speed control, proceed with ABS inspection. ^ If none of the above apply, no further action is required, release the vehicle. SPEED CONTROL SERVO INSPECTION 1. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage (See Figure 6) ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector) proceed to step 2 for further instructions. ^ If heat damage is found proceed as follows: - 1999-2003 Windstar complete ABS inspection before calling the Special Service Support Center for further instructions. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9884 - All other vehicles call the Special Service Support Center for further instructions. 2. With the speed control servo disconnected use shop air to blow out any trace of brake fluid from the speed control servo harness electrical connector and the servo module. Do not use any type of solvent to clean the connectors. 3. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II (XG-15-A) across the entire width and length of the servo vehicle harness connector (See Figure 7). NOTICE: Be sure to apply an adequate amount of grease to the vehicle harness connector only DO NOT apply the grease directly to the connector of the servo module. 4. Reconnect the harness to the servo module. 5. If the vehicle is a 1999-2OO3 Windstar proceed to ABS inspection. Otherwise no further action is required, release the vehicle. ANTI-LOCK BRAKE SYSTEM (ABS) INSPECTION NOTE: This inspection applies to 1999 through 2003 Windstar vehicles only. 1. Lift vehicle and remove ABS cover. 2. Disconnect ABS module. Inspect the ABS harness and module connectors for the presence of brake fluid. 3. If brake fluid is present use shop air to blow out any trace of brake fluid from the harness connector and module. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9885 4. Inspect the ABS harness and module connectors for corrosion and/or heat damage (See Figure 8). 5. If evidence of corrosion and/or heat damage is found in either the ABS harness or module connector call the Special Service Support Center for further instructions. 6. If there is no evidence of corrosion and/or heat damage reconnect the ABS harness to the ABS module. 7. Is the speed control servo heat damaged? ^ If the speed control servo is heat damaged call the Special Service Support Center for further instructions. ^ If the speed control servo is not heat damaged no further action is required release the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9886 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 9887 Owner Letter Owner Letter not available at this time. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications Cruise Control Servo: Specifications Speed Control Servo Bracket Bolt 9-12 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 9891 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 9892 Cruise Control Servo: Service Precautions WARNING: INCORRECT WRAPPING OF THE SPEED CONTROL ACTUATOR CABLE AROUND THE SPEED CONTROL SERVO PULLEY MAY RESULT IN A HIGH IDLE CONDITION. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 9893 Cruise Control Servo: Service and Repair REMOVAL 1. Disconnect the speed control servo electrical connector. 2. Remove the speed control actuator cable cap from the speed control servo. ^ Push the locking arm on the speed control actuator cable cap then rotate the cap counterclockwise. 3. Disconnect the speed control core wire end from the speed control servo pulley. 1 Depress the spring retainer. 2 Slide the core wire end out of the speed control servo pulley. 4. Remove the speed control servo bracket bolt. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 9894 5. Remove the speed control servo. INSTALLATION 1. Install the speed control servo bracket bolt. 2. Insert the speed control cable slug into the speed control servo pulley slot. 1 Gently compress the speed control servo spring. 2 Insert the speed control cable slug into the speed control servo pulley slot. 3. Release the compressed spring while aligning the speed control actuator cable cap tabs with the slots in the speed control servo housing. WARNING: INCORRECT WRAPPING OF THE SPEED CONTROL ACTUATOR CABLE AROUND THE SPEED CONTROL SERVO PULLEY MAY RESULT IN A HIGH IDLE CONDITION. NOTE: Make sure the rubber seal is fully seated onto the speed control actuator cable cap. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 9895 4. Rotate the speed control actuator cable cap until the locking arm engages. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement Technical Service Bulletin # 03S03 Date: 030801 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 9904 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 9905 Attachment I - Administrative Information OASIS Use OASIS to determine if a vehicle is eligible for this recall. Note: Some of the vehicles affected by this program are also affected by program 03S04. Affected customers will receive one letter describing both programs. For customer convenience please perform both programs during one customer visit. PROMPTLY CORRECT Promptly correct all affected in-stock and sold vehicles on your FSA VIN Lists. Also correct other affected vehicles identified in OASIS which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any of your affected owners whose names are not on your VIN lists but identified in OASIS. Give the owner a copy of the Owner Letter and schedule a service date. Note: Your FSA VIN list may contain customer names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states provinces and countries. Accordingly you must limit the use of this listing to the follow- up necessary to complete this action. Advise regional office if an owner cannot be contacted or does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company is offering a refund for owner-paid repairs covered by this Safety Recall if the repair was performed prior to the date indicated in the reimbursement plan which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or at their option directly through Ford Motor Company at P.O. Box 1904, Dearborn, MI 48121. Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 9906 specified in the reimbursement plan. Refund Claiming Information Program Code: 03S03 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hrs. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels as noted below. For the first 30 days after program launch emergency status orders can be placed by calling the Special Service Support Center at 1-800-325-5621. ^ For Stock Orders effective immediately follow normal order process. ^ For Interim Orders effective immediately follow normal order process. ^ For Emergency Orders within the first 30 days after launch call 1-800-325-5621. For Emergency Orders 31 days after launch follow normal order process. The DOR/COR for this program is 50308. This number identifies parts ordered for this recall through the Special Service Support Center (1-800-325-5621). USE OF "CHECKING GAUGE" A "Checking Gauge" is utilized in this recall during Step 6 of the Technical Instructions. Gauges will be shipped to the dealership (quantity of 4 gauges per dealer). It is expected that tools will arrive at the dealership the week of September 2, 2003. A limited number of additional gauges may be ordered at no-charge by calling the Special Service Support Center at 1-800-325-5621. Alternatively, dealers can use an accurate measuring device such as digital calipers. PARTS RETENTION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 9907 Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." DEALER PRICE For latest prices, refer to DOES II or 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. Attachment III - Technical Information INSPECTION 1. Locate the speed control cable identification number. Read the second to last letter. See Figure 1. ^ If the letter is a "T", no service is required. Release the vehicle. If the letter is a "D", continue with this inspection. 2. Remove the snow/ice shield. See Figure 2. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 9908 3. Visually inspect the cable for any of the following unacceptable conditions (see Figure 3): ^ Cover flared or split. ^ Core wire exposed when no tension is applied to the cable. ^ Cable is kinked. Replace the cable if any of the above conditions are found. For replacement and adjustment procedures, refer to Section 310-03, Vehicle Speed Control of the appropriate workshop manual. If none of these conditions are found, continue with the next step of this procedure. 4. WARNING: BE SURE TO MARK THE STRAND COVER AT THE VERY POINT WHERE IT ENTERS THE NOTCHED CABLE HOUSING. FAILURE TO MARK THE COVER AND MEASURE THE DISTANCE ACCURATELY (AS OUTLINED IN STEP 6) MAY RESULT IN FAILURE TO REPLACE AN UNACCEPTABLE CABLE. NOTE: Use a suitable marker such as a fine point paint marker or a felt-tipped marking pen. Brush-on touchup paint may also be used. DO NOT use a blunt marker or one that has a worn-out tip. It could cause your measurement to be incorrect. Whichever marking device you decide to use, it must leave a clean, straight line at the very point where the strand cover enters the notched cable housing. You will be measuring, in very small increments, the distance from the very edge of the mark you make to a certain point on the cable assembly. THE MEASUREMENT MUST NOT INCLUDE THE THICKNESS OF THE MARK. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 9909 Clean the cable if necessary, then using a suitable marking device, mark the strand cover at the point where the cover enters the notched cable housing. See Figure 4. 5. Disconnect the speed control cable connector from the throttle body cam by pulling the connector upward. See Figure 4. 6. CAUTION: When performing the following check, you will be instructed to pull the connector taut. Use only your hand to pull the connector. DO NOT use any type of tool to do this or damage to the cable may occur. CAUTION: Do not grasp the cable so tightly that you will kink the cable. NOTE: When pulling the connector, the strand cover may or may not be pulled out of the notched cable housing. For the purpose of this inspection, either is acceptable. NOTE: The following check can be made using either the 4 mm checking gauge supplied to each dealership or a Vernier caliper (analog dial or electronic LCD display). Pull the connector taut (toward the front of the vehicle). See Figure 5. A) If the strand cover does not pull out of the notched cable housing, no further service is required. Reattach the connector to the throttle body cam, install the snow/ice shield and release the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 9910 B) If the strand cover is pulled out of the notched cable housing, using either the supplied 4 mm checking gauge or a Vernier caliper, measure the distance from the inside edge of the mark to the end of the exposed strand cover. Do not include the thickness of the mark when taking the measurement. See Figures 5 and 6. ^ If the measurement is 4 mm (5/32-inch or 0.157-inch) or greater, no further service is required. Reattach the connector to the throttle body cam, install the snow/ice shield and release the vehicle. ^ If the measurement is less than 4 mm (5/32-inch or 0.157-inch), the speed control cable must be replaced. For replacement and adjustment procedures, refer to Section 310-03, Vehicle Speed Control of the appropriate workshop manual. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 9911 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 9912 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement Technical Service Bulletin # 03S03 Date: 030801 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 9918 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 9919 Attachment I - Administrative Information OASIS Use OASIS to determine if a vehicle is eligible for this recall. Note: Some of the vehicles affected by this program are also affected by program 03S04. Affected customers will receive one letter describing both programs. For customer convenience please perform both programs during one customer visit. PROMPTLY CORRECT Promptly correct all affected in-stock and sold vehicles on your FSA VIN Lists. Also correct other affected vehicles identified in OASIS which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any of your affected owners whose names are not on your VIN lists but identified in OASIS. Give the owner a copy of the Owner Letter and schedule a service date. Note: Your FSA VIN list may contain customer names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states provinces and countries. Accordingly you must limit the use of this listing to the follow- up necessary to complete this action. Advise regional office if an owner cannot be contacted or does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company is offering a refund for owner-paid repairs covered by this Safety Recall if the repair was performed prior to the date indicated in the reimbursement plan which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or at their option directly through Ford Motor Company at P.O. Box 1904, Dearborn, MI 48121. Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 9920 specified in the reimbursement plan. Refund Claiming Information Program Code: 03S03 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hrs. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels as noted below. For the first 30 days after program launch emergency status orders can be placed by calling the Special Service Support Center at 1-800-325-5621. ^ For Stock Orders effective immediately follow normal order process. ^ For Interim Orders effective immediately follow normal order process. ^ For Emergency Orders within the first 30 days after launch call 1-800-325-5621. For Emergency Orders 31 days after launch follow normal order process. The DOR/COR for this program is 50308. This number identifies parts ordered for this recall through the Special Service Support Center (1-800-325-5621). USE OF "CHECKING GAUGE" A "Checking Gauge" is utilized in this recall during Step 6 of the Technical Instructions. Gauges will be shipped to the dealership (quantity of 4 gauges per dealer). It is expected that tools will arrive at the dealership the week of September 2, 2003. A limited number of additional gauges may be ordered at no-charge by calling the Special Service Support Center at 1-800-325-5621. Alternatively, dealers can use an accurate measuring device such as digital calipers. PARTS RETENTION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 9921 Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." DEALER PRICE For latest prices, refer to DOES II or 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. Attachment III - Technical Information INSPECTION 1. Locate the speed control cable identification number. Read the second to last letter. See Figure 1. ^ If the letter is a "T", no service is required. Release the vehicle. If the letter is a "D", continue with this inspection. 2. Remove the snow/ice shield. See Figure 2. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 9922 3. Visually inspect the cable for any of the following unacceptable conditions (see Figure 3): ^ Cover flared or split. ^ Core wire exposed when no tension is applied to the cable. ^ Cable is kinked. Replace the cable if any of the above conditions are found. For replacement and adjustment procedures, refer to Section 310-03, Vehicle Speed Control of the appropriate workshop manual. If none of these conditions are found, continue with the next step of this procedure. 4. WARNING: BE SURE TO MARK THE STRAND COVER AT THE VERY POINT WHERE IT ENTERS THE NOTCHED CABLE HOUSING. FAILURE TO MARK THE COVER AND MEASURE THE DISTANCE ACCURATELY (AS OUTLINED IN STEP 6) MAY RESULT IN FAILURE TO REPLACE AN UNACCEPTABLE CABLE. NOTE: Use a suitable marker such as a fine point paint marker or a felt-tipped marking pen. Brush-on touchup paint may also be used. DO NOT use a blunt marker or one that has a worn-out tip. It could cause your measurement to be incorrect. Whichever marking device you decide to use, it must leave a clean, straight line at the very point where the strand cover enters the notched cable housing. You will be measuring, in very small increments, the distance from the very edge of the mark you make to a certain point on the cable assembly. THE MEASUREMENT MUST NOT INCLUDE THE THICKNESS OF THE MARK. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 9923 Clean the cable if necessary, then using a suitable marking device, mark the strand cover at the point where the cover enters the notched cable housing. See Figure 4. 5. Disconnect the speed control cable connector from the throttle body cam by pulling the connector upward. See Figure 4. 6. CAUTION: When performing the following check, you will be instructed to pull the connector taut. Use only your hand to pull the connector. DO NOT use any type of tool to do this or damage to the cable may occur. CAUTION: Do not grasp the cable so tightly that you will kink the cable. NOTE: When pulling the connector, the strand cover may or may not be pulled out of the notched cable housing. For the purpose of this inspection, either is acceptable. NOTE: The following check can be made using either the 4 mm checking gauge supplied to each dealership or a Vernier caliper (analog dial or electronic LCD display). Pull the connector taut (toward the front of the vehicle). See Figure 5. A) If the strand cover does not pull out of the notched cable housing, no further service is required. Reattach the connector to the throttle body cam, install the snow/ice shield and release the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 9924 B) If the strand cover is pulled out of the notched cable housing, using either the supplied 4 mm checking gauge or a Vernier caliper, measure the distance from the inside edge of the mark to the end of the exposed strand cover. Do not include the thickness of the mark when taking the measurement. See Figures 5 and 6. ^ If the measurement is 4 mm (5/32-inch or 0.157-inch) or greater, no further service is required. Reattach the connector to the throttle body cam, install the snow/ice shield and release the vehicle. ^ If the measurement is less than 4 mm (5/32-inch or 0.157-inch), the speed control cable must be replaced. For replacement and adjustment procedures, refer to Section 310-03, Vehicle Speed Control of the appropriate workshop manual. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 9925 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable Inspection/Replacement > Page 9926 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > Page 9927 Cruise Control Servo Cable: Specifications Accelerator Control Splash Shield Bolt (4.0L [Push Rod], 5.0L) .......... 8-12 Nm ............ (71-106Lb-In) Accelerator Control Splash Shield Bolts (4.0L SOHC) ......................... 3.1-4.3 Nm ........ (2.5-3 Lb-Ft) Battery Ground Cable .......................................................................7-10 Nm ............ (62-89 Lb-In) Speed Control Actuator Cable Bolt .....................................................3.1-4.3 Nm ........ (27-38 Lb-In) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service Precautions > Technician Safety Information Cruise Control Servo Cable: Technician Safety Information WARNING: INCORRECT WRAPPING OF THE SPEED CONTROL ACTUATOR CABLE AROUND THE SPEED CONTROL SERVO PULLEY MAY RESULT IN A HIGH IDLE CONDITION. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service Precautions > Technician Safety Information > Page 9930 Cruise Control Servo Cable: Vehicle Damage Warnings CAUTION: The guide pin must be fully seated before installing the speed control actuator cable bolt. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service Precautions > Page 9931 Cruise Control Servo Cable: Adjustments REMOVAL 1. Remove the speed control actuator cable clip. 2. Adjust the speed control actuator cable. 1 Make sure the throttle body cam is in the closed position. 2 Pull on the speed control actuator cable to remove any slack. 3 Back off the speed control actuator cable one notch. NOTE ^ The speed control actuator cable must not be pulled tight for proper operation. ^ The throttle body cam will automatically spring set to the closed position. The throttle body cam must be in the closed position. INSTALLATION 1. Install the speed control actuator cable clip. 1 Hold the speed control actuator cable. 2 Insert the speed control actuator clip securely. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service Precautions > Page 9932 Cruise Control Servo Cable: Service and Repair REMOVAL 1. Remove the accelerator control splash shield. Remove the bolts. 2. Remove the speed control actuator cable . 1 Remove the bolt. 2 Remove the speed control actuator cable from the throttle linkage. 3. Remove the speed control actuator cable cap from the speed control servo. ^ Push in the locking arm on the speed control actuator cable cap then rotate the cap counterclockwise. 4. Disconnect the speed control core wire end from the speed control servo pulley. 1 Depress the spring retainer. 2 Slide the core wire end out of the speed control servo pulley. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service Precautions > Page 9933 INSTALLATION 1. Insert the speed control cable slug into the speed control servo pulley slot. 1 Gently compress the speed control servo spring. 2 Insert the speed control cable slug into the speed control servo pulley slot. 2. Release the compressed spring while aligning the speed control actuator cable cap tabs with the slots in the speed control servo housing. WARNING: INCORRECT WRAPPING OF THE SPEED CONTROL ACTUATOR CABLE AROUND THE SPEED CONTROL SERVO PULLEY MAY RESULT IN A HIGH IDLE CONDITION. NOTE: Make sure the rubber seal is fully seated onto the speed control actuator cable cap. 3. Rotate the speed control actuator cable cap until the locking arm engages. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service Precautions > Page 9934 4. Snap the speed control actuator cable and the accelerator cable together in the clip and install the cables onto the accelerator cable bracket. CAUTION: The guide pin must be fully seated before installing the speed control actuator cable bolt. 5. Position the accelerator control splash shield and install the bolts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Recalls for Cruise Control Switch: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Cruise Control Switch: Recalls Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Cruise Control Switch: All Technical Service Bulletins Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 9948 Cruise Control Switch: Specifications Speed Control Actuator Switch Screws 6.5-7.5 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 9949 Cruise Control Switch: Service Precautions CAUTION: When separating the speed control actuator switch from the steering wheel, it is necessary to take precautions not to damage the steering wheel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Without Remote Audio Cruise Control Switch: Service and Repair Without Remote Audio REMOVAL 1. Remove the driver side air bag module. Refer to Air Bag Systems. 2. Remove the speed control actuator switches. 1 Remove the screws. 2 Disconnect the electrical connector then remove the speed control actuator switches. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16km (10 miles) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Without Remote Audio > Page 9952 Cruise Control Switch: Service and Repair With Remote Audio REMOVAL 1. Disconnect the battery ground cable. 2. Separate the speed control actuator switch out of the steering wheel. CAUTION: When separating the speed control actuator switch from the steering wheel, it is necessary to take precautions not to damage the steering wheel. 3. Remove the speed control actuator switch. 1 Disconnect the speed control actuator switch electrical connector. 2 Remove the speed control actuator switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn its strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Brake Switch (Cruise Control): Recalls Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9966 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9967 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9968 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9969 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9970 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9971 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9972 Attachment III - Technical Information Table of Contents Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9973 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9974 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9975 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9976 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9977 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9978 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9979 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9980 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9981 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9982 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9983 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9984 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9985 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9986 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9987 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9988 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9989 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9990 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9991 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 9996 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Brake Switch (Cruise Control): All Technical Service Bulletins Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10006 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10007 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10008 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10009 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10010 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10011 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10012 Attachment III - Technical Information Table of Contents Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10013 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10014 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10015 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10016 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10017 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10018 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10019 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10020 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10021 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10022 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10023 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10024 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10025 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10026 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10027 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10028 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10029 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10030 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10031 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): All Technical Service Bulletins Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 10036 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 10037 Brake Switch (Cruise Control): Specifications Deactivator Switch 15-20 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Technician Safety Information Brake Switch (Cruise Control): Technician Safety Information WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Technician Safety Information > Page 10040 Brake Switch (Cruise Control): Vehicle Damage Warnings 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. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Page 10041 Brake Switch (Cruise Control): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the deactivator switch electrical connector. 3. Remove the deactivator switch. WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES 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: 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. INSTALLATION 1. To install, reverse the removal procedure. NOTE ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. ^ After the deactivator switch is installed, it is necessary to bleed the brake system; refer to Brakes. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating Technical Service Bulletin # 09S09 Date: 091013 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10050 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on October 13, 2009. NOTE: This recall pertains to certain vehicles that have a factory installed speed control deactivation switch only. Ford offered a Genuine Accessory Speed Control kit that utilized a production steering wheel identical to the factory-installed system. The Ford accessory kit does not use a master cylinder mounted deactivation switch and, as a result, vehicles with this kit are not included in this recall. If a customer inquires about Safety Recall 09509, and the VIN of their vehicle is not listed in OASIS under 09509, the vehicle is not involved in the program. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by October 15, 2009. Owner names and addresses will be available by December 18, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10051 RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Ford Motor Company is offering a refund for owner paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ Refunds will only be provided for the cost associated with repairs due to a leaking speed control deactivation switch. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 09S09 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. ^ Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim. If a repair is performed on the same visit, the repair and refunds should be submitted on separate repair lines. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. ^ Claiming information for Electrical Grease II for servicing both the speed control servo and SCDS adapter jumper harness connector - applies to Labor Operation 09509G or 09S09H. (Submit on same repair line as repair.) - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $6.30 ^ Claiming information for Electrical Grease II for servicing SCDS adapter jumper harness connector only - applies to Labor Operation 09509D, 09509F or 09509J (Submit on same repair line as repair.) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10052 - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $0.50 Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10053 PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this safety recall is 50409. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Affected speed control deactivation switches and related damage parts are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10054 TABLE OF CONTENTS OVERVIEW This Safety Recall involves an inspection of the Speed Control Deactivation Switch (SCDS) harness connector for the presence of brake fluid contamination. If no brake fluid is present, install the universal fused jumper harness. If brake fluid is present, replace the SCDS and inspect the speed control servo harness connector for heat damage. See Flow Chart # 2. In addition, for 1999 through 2003 Windstar vehicles, the repair includes an inspection of the Anti-lock Brake System (ABS) connectors. See Flow Chart # 2. If a related damage condition is found that you believe to be caused by a leaking SCDS, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. REPAIR FLOW CHARTS Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10055 Flow Chart # 1 shows the repair procedure for all affected vehicles except 1999 through 2003 Windstar vehicles. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10056 Flow Chart # 2 shows the repair procedure for 1999 through 2003 Windstar vehicles. SCDS Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10057 The Speed Control Deactivation Switch (SCDS) involved in Safety Recall 09S09 and the revised SCDS are illustrated (See Figure 1). Note that the revised SCDS has a different electrical connector An adapter jumper harness (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS SCDS Location In most vehicles involved in this recall, the SCDS is located on the master cylinder. In 1992-1993 E-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail under the driver's seat. In 1993 F-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail below the master cylinder To verify, just follow the metal brake lines from the master cylinder until the switch is found On F-53 Motorhome vehicles, if the SCDS is not located on the master cylinder, it maybe located in a brake line junction block approximately 457 mm (18 in) below the master cylinder It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. SCDS INSPECTION PROCEDURE NOTE: For E-Series vehicles, there is a possibility that the vehicle was manufactured without a SCDS If unable to locate a SCDS after checking on all the brake lines, no further action is required, release the vehicle NOTE: On 1992-1993 E-Series and 1993 F-Series vehicles, it may be necessary to lift the vehicle to gain access to the SCDS On Windstar vehicles, the air cleaner housing must be separated in the middle to gain access to the SCDS Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10058 1. Disconnect the harness connector from the SCDS (See Figure 2) 2. Inspect the harness connector for the presence of brake fluid. ^ If there is no evidence of brake fluid on the connector, install Universal Fused Jumper Harness (UFJH). ^ If there is evidence of brake fluid on the connector, replace SCDS. UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION 1. Connect the Universal Fused Jumper Harness (UFJH) to the SCDS and the vehicle harness. 2. Secure the UFJH to the existing harness with tie straps making sure the fuse holders are positioned vertically with the fuse holder cap facing upward Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10059 Wrap the tie straps underneath then over the top of the existing harness and verify proper fuse holder orientation (See Figure 3). 3. No further action is required release the vehicle. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and if necessary fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS (See Figure 4). NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed 3. Remove the old SCDS. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft). 5. Check the brake fluid level at the master cylinder fill to maximum fluid level and install the brake fluid reservoir cap. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10060 6. Before installing the adapter jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II (XG-15-A) (See Figure 5). 7. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the adapter jumper harness to a nearby component such as the speed control cable or another wire harness. ^ If the vehicle has a speed control servo, proceed with speed control servo inspection. ^ If the vehicle is a 1999-2003 Windstar that does not have speed control, proceed with ABS inspection. ^ If none of the above apply, no further action is required, release the vehicle. SPEED CONTROL SERVO INSPECTION 1. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage (See Figure 6) ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector) proceed to step 2 for further instructions. ^ If heat damage is found proceed as follows: - 1999-2003 Windstar complete ABS inspection before calling the Special Service Support Center for further instructions. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10061 - All other vehicles call the Special Service Support Center for further instructions. 2. With the speed control servo disconnected use shop air to blow out any trace of brake fluid from the speed control servo harness electrical connector and the servo module. Do not use any type of solvent to clean the connectors. 3. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II (XG-15-A) across the entire width and length of the servo vehicle harness connector (See Figure 7). NOTICE: Be sure to apply an adequate amount of grease to the vehicle harness connector only DO NOT apply the grease directly to the connector of the servo module. 4. Reconnect the harness to the servo module. 5. If the vehicle is a 1999-2OO3 Windstar proceed to ABS inspection. Otherwise no further action is required, release the vehicle. ANTI-LOCK BRAKE SYSTEM (ABS) INSPECTION NOTE: This inspection applies to 1999 through 2003 Windstar vehicles only. 1. Lift vehicle and remove ABS cover. 2. Disconnect ABS module. Inspect the ABS harness and module connectors for the presence of brake fluid. 3. If brake fluid is present use shop air to blow out any trace of brake fluid from the harness connector and module. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10062 4. Inspect the ABS harness and module connectors for corrosion and/or heat damage (See Figure 8). 5. If evidence of corrosion and/or heat damage is found in either the ABS harness or module connector call the Special Service Support Center for further instructions. 6. If there is no evidence of corrosion and/or heat damage reconnect the ABS harness to the ABS module. 7. Is the speed control servo heat damaged? ^ If the speed control servo is heat damaged call the Special Service Support Center for further instructions. ^ If the speed control servo is not heat damaged no further action is required release the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10063 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10064 Owner Letter Owner Letter not available at this time. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating Technical Service Bulletin # 09S09 Date: 091013 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10070 Attachment I - Administrative Information OASIS ACTIVATED? Yes, OASIS will be activated on October 13, 2009. NOTE: This recall pertains to certain vehicles that have a factory installed speed control deactivation switch only. Ford offered a Genuine Accessory Speed Control kit that utilized a production steering wheel identical to the factory-installed system. The Ford accessory kit does not use a master cylinder mounted deactivation switch and, as a result, vehicles with this kit are not included in this recall. If a customer inquires about Safety Recall 09509, and the VIN of their vehicle is not listed in OASIS under 09509, the vehicle is not involved in the program. FSA VIN LIST ACTIVATED? Yes, FSA VIN list will be available through the website by October 15, 2009. Owner names and addresses will be available by December 18, 2009. NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action. STOCK VEHICLES Correct all affected units in your vehicle inventory before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date. ^ Correct other affected vehicles identified in OASIS which are brought to your dealership. TITLE BRANDED / SALVAGED VEHICLES Affected title branded and salvaged vehicles are eligible for this Field Service Action. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10071 RELATED DAMAGE If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. ADDITIONAL LABOR TIME ^ If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior to performing any additional labor. Requests for approval after completion of the repair will not be granted. ^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Ford Motor Company is offering a refund for owner paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan, which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed. ^ Refunds will only be provided for the cost associated with repairs due to a leaking speed control deactivation switch. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 09S09 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. ^ Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim. If a repair is performed on the same visit, the repair and refunds should be submitted on separate repair lines. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refer to ACESII manual for claims preparation and submission information. ^ Refunds or related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed. Related damage requires prior approval from the Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires prior approval from the Special Service Support Center. ^ Claiming information for Electrical Grease II for servicing both the speed control servo and SCDS adapter jumper harness connector - applies to Labor Operation 09509G or 09S09H. (Submit on same repair line as repair.) - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $6.30 ^ Claiming information for Electrical Grease II for servicing SCDS adapter jumper harness connector only - applies to Labor Operation 09509D, 09509F or 09509J (Submit on same repair line as repair.) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10072 - Program Code: 09S09 - Misc. Expense: OTHER - Misc. Expense: $0.50 Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10073 PARTS REQUIREMENTS / ORDERING INFORMATION Order your parts requirements through normal order processing channels. The DOR/COR number for this safety recall is 50409. Questions regarding parts should be directed to the Special Service Support Center or E-mailed. DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Affected speed control deactivation switches and related damage parts are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS (Parts Entry and Return System) register for part disposition and return instructions. Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10074 TABLE OF CONTENTS OVERVIEW This Safety Recall involves an inspection of the Speed Control Deactivation Switch (SCDS) harness connector for the presence of brake fluid contamination. If no brake fluid is present, install the universal fused jumper harness. If brake fluid is present, replace the SCDS and inspect the speed control servo harness connector for heat damage. See Flow Chart # 2. In addition, for 1999 through 2003 Windstar vehicles, the repair includes an inspection of the Anti-lock Brake System (ABS) connectors. See Flow Chart # 2. If a related damage condition is found that you believe to be caused by a leaking SCDS, call the Special Service Support Center to request approval prior to the repair of any related damage. Requests for approval after completion of the repair will not be granted. REPAIR FLOW CHARTS Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10075 Flow Chart # 1 shows the repair procedure for all affected vehicles except 1999 through 2003 Windstar vehicles. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10076 Flow Chart # 2 shows the repair procedure for 1999 through 2003 Windstar vehicles. SCDS Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10077 The Speed Control Deactivation Switch (SCDS) involved in Safety Recall 09S09 and the revised SCDS are illustrated (See Figure 1). Note that the revised SCDS has a different electrical connector An adapter jumper harness (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS SCDS Location In most vehicles involved in this recall, the SCDS is located on the master cylinder. In 1992-1993 E-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail under the driver's seat. In 1993 F-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve on the left frame rail below the master cylinder To verify, just follow the metal brake lines from the master cylinder until the switch is found On F-53 Motorhome vehicles, if the SCDS is not located on the master cylinder, it maybe located in a brake line junction block approximately 457 mm (18 in) below the master cylinder It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. SCDS INSPECTION PROCEDURE NOTE: For E-Series vehicles, there is a possibility that the vehicle was manufactured without a SCDS If unable to locate a SCDS after checking on all the brake lines, no further action is required, release the vehicle NOTE: On 1992-1993 E-Series and 1993 F-Series vehicles, it may be necessary to lift the vehicle to gain access to the SCDS On Windstar vehicles, the air cleaner housing must be separated in the middle to gain access to the SCDS Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10078 1. Disconnect the harness connector from the SCDS (See Figure 2) 2. Inspect the harness connector for the presence of brake fluid. ^ If there is no evidence of brake fluid on the connector, install Universal Fused Jumper Harness (UFJH). ^ If there is evidence of brake fluid on the connector, replace SCDS. UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION 1. Connect the Universal Fused Jumper Harness (UFJH) to the SCDS and the vehicle harness. 2. Secure the UFJH to the existing harness with tie straps making sure the fuse holders are positioned vertically with the fuse holder cap facing upward Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10079 Wrap the tie straps underneath then over the top of the existing harness and verify proper fuse holder orientation (See Figure 3). 3. No further action is required release the vehicle. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and if necessary fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS (See Figure 4). NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed 3. Remove the old SCDS. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft). 5. Check the brake fluid level at the master cylinder fill to maximum fluid level and install the brake fluid reservoir cap. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10080 6. Before installing the adapter jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II (XG-15-A) (See Figure 5). 7. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the adapter jumper harness to a nearby component such as the speed control cable or another wire harness. ^ If the vehicle has a speed control servo, proceed with speed control servo inspection. ^ If the vehicle is a 1999-2003 Windstar that does not have speed control, proceed with ABS inspection. ^ If none of the above apply, no further action is required, release the vehicle. SPEED CONTROL SERVO INSPECTION 1. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage (See Figure 6) ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector) proceed to step 2 for further instructions. ^ If heat damage is found proceed as follows: - 1999-2003 Windstar complete ABS inspection before calling the Special Service Support Center for further instructions. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10081 - All other vehicles call the Special Service Support Center for further instructions. 2. With the speed control servo disconnected use shop air to blow out any trace of brake fluid from the speed control servo harness electrical connector and the servo module. Do not use any type of solvent to clean the connectors. 3. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II (XG-15-A) across the entire width and length of the servo vehicle harness connector (See Figure 7). NOTICE: Be sure to apply an adequate amount of grease to the vehicle harness connector only DO NOT apply the grease directly to the connector of the servo module. 4. Reconnect the harness to the servo module. 5. If the vehicle is a 1999-2OO3 Windstar proceed to ABS inspection. Otherwise no further action is required, release the vehicle. ANTI-LOCK BRAKE SYSTEM (ABS) INSPECTION NOTE: This inspection applies to 1999 through 2003 Windstar vehicles only. 1. Lift vehicle and remove ABS cover. 2. Disconnect ABS module. Inspect the ABS harness and module connectors for the presence of brake fluid. 3. If brake fluid is present use shop air to blow out any trace of brake fluid from the harness connector and module. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10082 4. Inspect the ABS harness and module connectors for corrosion and/or heat damage (See Figure 8). 5. If evidence of corrosion and/or heat damage is found in either the ABS harness or module connector call the Special Service Support Center for further instructions. 6. If there is no evidence of corrosion and/or heat damage reconnect the ABS harness to the ABS module. 7. Is the speed control servo heat damaged? ^ If the speed control servo is heat damaged call the Special Service Support Center for further instructions. ^ If the speed control servo is not heat damaged no further action is required release the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10083 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10084 Owner Letter Owner Letter not available at this time. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Recalls for Cruise Control Switch: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Cruise Control Switch: Recalls Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch Cruise Control Switch: All Technical Service Bulletins Recall 09V399000: Cruise Control Deactivation Switch VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion 2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994 Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002 MANUFACTURER: Ford Motor Company MFR'S REPORT DATE: October 09, 2009 NHTSA CAMPAIGN ID NUMBER: 09V399000 NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 4500000 SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997 and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then overheat, smoke, or burn. CONSEQUENCE: A vehicle fire could occur. REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS. Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be completed free of charge. The safety recall is expected to begin on or about October 26, 2009. Owners may contact Ford at 1-800-392-3673. NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 10098 Cruise Control Switch: Specifications Speed Control Actuator Switch Screws 6.5-7.5 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 10099 Cruise Control Switch: Service Precautions CAUTION: When separating the speed control actuator switch from the steering wheel, it is necessary to take precautions not to damage the steering wheel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Without Remote Audio Cruise Control Switch: Service and Repair Without Remote Audio REMOVAL 1. Remove the driver side air bag module. Refer to Air Bag Systems. 2. Remove the speed control actuator switches. 1 Remove the screws. 2 Disconnect the electrical connector then remove the speed control actuator switches. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16km (10 miles) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Without Remote Audio > Page 10102 Cruise Control Switch: Service and Repair With Remote Audio REMOVAL 1. Disconnect the battery ground cable. 2. Separate the speed control actuator switch out of the steering wheel. CAUTION: When separating the speed control actuator switch from the steering wheel, it is necessary to take precautions not to damage the steering wheel. 3. Remove the speed control actuator switch. 1 Disconnect the speed control actuator switch electrical connector. 2 Remove the speed control actuator switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn its strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Locations > Page 10107 ABS Light: Description and Operation The Antilock Brake System (ABS) uses the yellow ABS warning indicator to alert the driver of a malfunctions in the ABS. The yellow ABS warning indicator will come on to warn the driver that the ABS has been turned off due to a symptom that exists in the ABS. Normal power assist braking remains but wheels can lock during a panic stop while the yellow ABS warning indicator is illuminated. The diagnostic procedures must be followed step-by-step in order to correct the condition. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Air Conditioning Indicator Lamp > Component Information > Service and Repair Air Conditioning Indicator Lamp: Service and Repair Climate Control Bulb For additional information, refer to Heating and Air Conditioning. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > Customer Interest for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set Audible Warning Device: Customer Interest Ignition Switch - High Turning Effort/MIL ON/DTC's Set Article No. 01-21-13 10/29/01 ^ DRIVEABILITY - DIAGNOSTIC TROUBLE CODES (DTC) P0500, P1502 AND/OR U1039 CONTINENTAL MODELS ONLY - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH ^ ELECTRICAL - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH FORD: 1998-2002 CROWN VICTORIA, MUSTANG, TAURUS 1998-1999 F-250 LD 1998-2001 EXPLORER 1998-2002 E SERIES, EXPEDITION, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC LINCOLN: 1998-2002 CONTINENTAL, TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 1998-2002 GRAND MARQUIS, SABLE 1998-2001 MOUNTAINEER ISSUE Some ignition switch lock cylinder assemblies may exhibit the following highly intermittent conditions: ^ Roughness and/or excessive effort in turning the key from RUN to START position. ^ Key does not fully return from START to RUN after starting vehicle. This may result in intermittent accessory function. ^ Continental ONLY - A malfunction indicator lamp may illuminate with diagnostic trouble codes P0500, P1502 and UlO3g stored in the Powertrain Control Modules (PCM) memory. This may be caused by a Key-In-Ignition warning chime switch. ACTION Replace the KEY-IN-IGNITION WARNING CHIME SWITCH located on the ignition switch lock cylinder with revised pant XL2Z-11A127-AB. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Disconnect the battery ground cable and wait at least one minute. 2. Insent the ignition key and turn it to the RUN position. 3. Insert a punch into the access hole (located in the lower steering column shroud, below the lock cylinder) and press the release button while pulling out the ignition switch lock cylinder. NOTE SOME VEHICLES DO NOT HAVE AN ACCESS HOLE AND REQUIRE LOWER SHROUD REMOVAL. REFER TO THE APPROPRIATE MODEL WORKSHOP MANUAL, IGNITION SWITCH LOCK CYLINDER REMOVAL AND INSTALLATION SECTION 211 IF ADDITIONAL DETAIL IS REQUIRED. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > Customer Interest for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set > Page 10119 4. Remove the Plastic Key chime warning switch by prying upward on the plastic retainer, while sliding the switch away from the key insertion end (Figure 1). Refer to the appropriate model Workshop Manual, Key-in-ignition warning switch removal and installation section located in Section 413 if additional detail is required. 5. Install a new Key-In-Ignition warning chime switch XL2Z-11A127-AB and reinstall lock cylinder. 6. Verify proper function of the Ignition Switch Lock Cylinder and Key-In-Ignition warning chime switch. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 012113A Replace The 0.3 Hr. Key-In-Ignition Warning Chime Switch DEALER CODING CONDITION BASIC PART NO. CODE 11A127 42 OASIS CODES: 102000, 112000, 202000, 203000, 204000, 204200, 205000, 206000, 207000, 208000, 208999, 301000, 302000, 497000, 504000, 601300, 603300, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set Audible Warning Device: All Technical Service Bulletins Ignition Switch - High Turning Effort/MIL ON/DTC's Set Article No. 01-21-13 10/29/01 ^ DRIVEABILITY - DIAGNOSTIC TROUBLE CODES (DTC) P0500, P1502 AND/OR U1039 CONTINENTAL MODELS ONLY - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH ^ ELECTRICAL - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH FORD: 1998-2002 CROWN VICTORIA, MUSTANG, TAURUS 1998-1999 F-250 LD 1998-2001 EXPLORER 1998-2002 E SERIES, EXPEDITION, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC LINCOLN: 1998-2002 CONTINENTAL, TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 1998-2002 GRAND MARQUIS, SABLE 1998-2001 MOUNTAINEER ISSUE Some ignition switch lock cylinder assemblies may exhibit the following highly intermittent conditions: ^ Roughness and/or excessive effort in turning the key from RUN to START position. ^ Key does not fully return from START to RUN after starting vehicle. This may result in intermittent accessory function. ^ Continental ONLY - A malfunction indicator lamp may illuminate with diagnostic trouble codes P0500, P1502 and UlO3g stored in the Powertrain Control Modules (PCM) memory. This may be caused by a Key-In-Ignition warning chime switch. ACTION Replace the KEY-IN-IGNITION WARNING CHIME SWITCH located on the ignition switch lock cylinder with revised pant XL2Z-11A127-AB. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Disconnect the battery ground cable and wait at least one minute. 2. Insent the ignition key and turn it to the RUN position. 3. Insert a punch into the access hole (located in the lower steering column shroud, below the lock cylinder) and press the release button while pulling out the ignition switch lock cylinder. NOTE SOME VEHICLES DO NOT HAVE AN ACCESS HOLE AND REQUIRE LOWER SHROUD REMOVAL. REFER TO THE APPROPRIATE MODEL WORKSHOP MANUAL, IGNITION SWITCH LOCK CYLINDER REMOVAL AND INSTALLATION SECTION 211 IF ADDITIONAL DETAIL IS REQUIRED. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set > Page 10125 4. Remove the Plastic Key chime warning switch by prying upward on the plastic retainer, while sliding the switch away from the key insertion end (Figure 1). Refer to the appropriate model Workshop Manual, Key-in-ignition warning switch removal and installation section located in Section 413 if additional detail is required. 5. Install a new Key-In-Ignition warning chime switch XL2Z-11A127-AB and reinstall lock cylinder. 6. Verify proper function of the Ignition Switch Lock Cylinder and Key-In-Ignition warning chime switch. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 012113A Replace The 0.3 Hr. Key-In-Ignition Warning Chime Switch DEALER CODING CONDITION BASIC PART NO. CODE 11A127 42 OASIS CODES: 102000, 112000, 202000, 203000, 204000, 204200, 205000, 206000, 207000, 208000, 208999, 301000, 302000, 497000, 504000, 601300, 603300, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10128 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10129 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10130 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10131 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10132 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10133 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10134 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10135 Audible Warning Device: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10136 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10137 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10138 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10139 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10140 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10141 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10142 Audible Warning Device: Electrical Diagrams Diagram 66-1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10143 Diagram 66-2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10144 Diagram 66-3 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 10145 Audible Warning Device: Description and Operation A short warning chime (0.1 second) is output with every message center switch press. A longer warning chime (1.0 second) is output when a new warning first appears on the message center indicator display. To activate the warning, the message center pulls the chime request output below one volt during the length of the tone. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 10146 Audible Warning Device: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is part of, please refer to Instrument Panel, Gauges and Warning indicators; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 10147 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device Control Module: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10153 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10154 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10155 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10156 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10157 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10158 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10159 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10160 Audible Warning Device Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10161 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10162 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10163 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10164 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10165 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10166 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Page 10167 Audible Warning Device Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Page 10168 Audible Warning Device Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Page 10169 Audible Warning Device Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Locations > Page 10173 Brake Warning Indicator: Description and Operation Brake System The red brake warning light (BRAKE) is used to indicate a low fluid level, brake malfunction or a parking brake that is not fully released. The brake fluid level switch is located in the brake fluid reservoir. The yellow brake warning indicator is used to indicate a malfunction or deactivation of the Anti-lock Brake System (ABS). It illuminates when triggered by the ABS control module and stays illuminated as long as the malfunction remains in the system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component Information > Description and Operation > Instrument Cluster Charge Lamp/Indicator: Description and Operation Instrument Cluster The charge system warning indicator illuminates when there is no generator (GEN) output. When the ignition switch contacts are closed, battery current flows through the charge indicator and the parallel resistor (390 ohm) to the voltage indicator, and the indicator illuminates. When the generator builds up enough voltage to energize a circuit in the voltage regulator, the indicator goes out. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component Information > Description and Operation > Instrument Cluster > Page 10179 Charge Lamp/Indicator: Description and Operation Information and Message Center This warning message is displayed when the electrical system is not maintaining correct voltage at the message center indicator. There will be a few seconds delay before the warning is displayed or removed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Locations > Page 10183 Check Gauges Lamp: Description and Operation The CHECK GAGE indicator will illuminate if any of the following occur: - Engine oil pressure drops below approximately 42 kPa (6 psi). - Fuel level drops below approximately 4-8 L (1-2 gal). - Engine temperature exceeds approximately 121°C (250°F). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10189 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10190 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10191 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10192 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10193 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10194 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10195 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10196 Cigarette Lighter: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10197 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10198 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10199 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10201 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10202 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10203 Diagram 44-2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations > Page 10207 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations > Page 10208 Compass: Service Precautions CAUTION: During demagnetizing, the demagnetizer coil will be pulled toward the vehicle. Place a cloth over the vehicle roof to protect the vehicle surface if contact occurs. Make sure the cloth covers the front third and the entire width of the roof. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations > Page 10209 Compass: Description and Operation A compass and outside temperature display are contained in the overhead console. The compass and temperature display can be turned off and on by pressing the MODE switch in the overhead console. The vehicle heading is displayed as one of N, NE, E, SE, S, SW, W, and NW. Compass Accuracy Magnetic mounted devices like antennas and luggage racks should not be located on the front third of the vehicle roof. Placing these devices near the compass will cause inaccurate directional readings. If these devices must be used, accuracy may be improved by recalibrating the compass while the devices are installed on the vehicle. Driving near power lines, or driving in the area of large iron or steel structures can temporarily change the compass heading. If the compass remains inaccurate after driving near such objects, demagnetize the vehicle and recalibrate the compass. Most geographic areas (zones) have a magnetic north compass point that varies slightly from the northerly direction on maps. This variation is four degrees between the adjacent zones and will become noticeable as the vehicle crosses multiple zones. A correct zone setting eliminates the error. Refer to Compass Zone Adjustment. See: Adjustments/Compass Zone Adjustment Temperature, Outside Air The thermometer sensor is attached to the radiator frame behind the grille. The temperature can be displayed in centigrade or Fahrenheit by pressing the MODE switch. If the outside temperature falls below 3.3°C (38°F), the display will alternate from "ICE" to the outside temperature at a two second rate for one minute. The outside air temperature reading can be affected by engine heat when the vehicle is idling or has been off for less than two hours. The compass and thermometer will limit the increase of the displayed temperature to one degree per minute at very low speeds or immediately after the ignition is turned on. After two minutes at a sustained speed of at least 53 km/h (33 mph), effects of engine heat are minimal and the compass will display the current outside temperature reading. Temperature decreases are always updated immediately. If the outside air temperature sensor is short or open circuited, then the display will show 60°C (140°F) or -40°C (-40°F) respectively in place of temperature. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Compass: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the compass and thermometer. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART 3. If inspection reveals an obvious concern(s) that can be readily identified, repair or replace as required. 4. If the fault is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10212 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10213 Compass: Pinpoint Tests Connector Circuit Reference Refer to the Vehicle/Diagrams for schematic and connector information. Pinpoint Test Notes NOTE: - Always set the zone, calibrate, and demagnetize a vehicle before replacing an inaccurate compass. - After replacing the compass, always set the zone and calibrate. Test A: Compass Is Inaccurate/Inoperative A1 - A2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10214 A3 - A4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10215 A5 - A6 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10216 A7 - A8 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10217 A9 - A10 Test B: Outside Air Temperature Is Inaccurate/Inoperative Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10218 B1 - B2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10219 B3 - B4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10220 B5 - B6 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10221 Special Service Tool(s) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Compass Zone Adjustment Compass: Adjustments Compass Zone Adjustment 1. Determine the zone in which the vehicle is located. 2. Press and hold the MODE button until VAR appears on the display. Release the MODE button. 3. Momentarily press the MODE button to increment the zone by one. Set the zone according to the map. NOTE: After a few seconds, the compass will exit the VAR mode if the button is no longer pressed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Compass Zone Adjustment > Page 10224 Compass: Adjustments Calibration Adjustment 1. Start the vehicle. NOTE: For optimum calibration, drive to an open, level location away from large metallic objects or structures. Switch off all non-essential electrical accessories (rear window defrost, heater A/C, map lamps, wipers, etc.) and make sure all doors are closed. 2. Locate the electronic compass/temperature display on the overhead console, press and hold the MODE button until CAL appears in the display, then release the MODE button. NOTE: To exit CAL mode before performing a compass adjustment, turn the ignition switch to the OFF position. 3. Drive the vehicle slowly (less than 5 km/h [3 mph]) in complete circles until CAL disappears from the display. NOTE: If the CAL indicator does not turn off after the vehicle has been driven in a circle no more than five times, demagnetize the vehicle and repeat the procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Compass Zone Adjustment > Page 10225 Compass: Adjustments Vehicle Demagnetizing CAUTION: During demagnetizing, the demagnetizer coil will be pulled toward the vehicle. Place a cloth over the vehicle roof to protect the vehicle surface if contact occurs. Make sure the cloth covers the front third and the entire width of the roof. NOTE: - The demagnetizing process requires the use of a demagnetizing coil commonly used by television repair technicians to demagnetize television tubes. - To demagnetize, use a constant circular motion over the vehicle roof. Do not turn off the demagnetizer while sweeping the vehicle roof to prevent remagnetizing ferrous materials contained in the vehicle. - During the demagnetizing process, make sure the phenolic surface of the tool (the side opposite the handle) is closest to the vehicle surface. 1. Demagnetize the front third of the vehicle roof. 1 Turn on the demagnetizer at least 1 m (3 ft) away from the vehicle. 2 Holding the demagnetizer no more than 2.5 cm (1 in) from the vehicle roof and starting on the passenger side, demagnetize the front third of the vehicle roof closest to the windshield using a constant circular motion. Keep the circle radius within 30 cm (12 in) while sweeping across the entire surface of the vehicle roof closest to the windshield. Continue the circular motion four times. 3 After the fourth pass and without stopping, move the demagnetizer at least 1 m (3 ft) away from the vehicle. 4 Turn the demagnetizer off. 2. Perform the Compass Zone Adjustment procedure. See: Compass Zone Adjustment 3. Perform the Compass Calibration Adjustment procedure. See: Calibration Adjustment Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Page 10226 Compass: Service and Repair REMOVAL 1. Remove the overhead console; refer to Interior Trim. 2. Remove the screws and disconnect the electrical connector. 3. Remove the compass/lamp bezel from the console housing. 1 Push the clip. 2 Remove the compass/lamp bezel from the console housing. 4. Remove the compass and thermometer. 1 Push the three locking tabs. 2 Remove the compass and thermometer. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Page 10227 Special Service Tool(s) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cruise Control Indicator Lamp > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cruise Control Indicator Lamp > Component Information > Locations > Page 10231 Cruise Control Indicator Lamp: Description and Operation The Speed Control Indicator (SPEED CONT) lamp will illuminate when the speed control is engaged. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING:To reduce the risk of personal injury, do not use any memory saver devices. NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram See: Restraint Systems/Air Bag Systems. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Disarming and Arming > Page 10237 7. Remove the two steering wheel back cover plugs. 8. Remove the two driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. 10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical connector at the clockspring. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Disarming and Arming > Page 10238 11. Open the glove compartment door to access the passenger air bag module mounting screws. 12. Remove the two screws. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove box opening, push out on the passenger air bag module and separate it from the instrument panel. 14. Disconnect the electrical connector and remove the passenger air bag module. 15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the passenger air bag module electrical connector. Vehicles equipped with seat side air bags Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Disarming and Arming > Page 10239 16. Disconnect the passenger seat side air bag module electrical connector located under the passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector located under the driver seat. 19. Connect the restraint system diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical connector. All vehicles 20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground cable. Reactivation Procedure All vehicles 1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles equipped with seat side air bags 3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side air bag module electrical connector located under the driver seat. 4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint system diagnostic tool from the body harness side of the passenger seat side air bag module electrical connector located under the passenger seat. 6. Connect the passenger seat side air bag module electrical connector All vehicles 7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air bag module electrical connector. 8. Install the passenger air bag module. 9. Connect the passenger air bag module electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Disarming and Arming > Page 10240 10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical connector at the clockspring. 11. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag module to the steering wheel. 12. Install the two driver air bag module retaining bolts. 13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON. 15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 17. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Disarming and Arming > Page 10241 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle battery connected? Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Disarming and Arming > Page 10242 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Prove out the system means to turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the upper and lower steering column shrouds. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Service and Repair > Page 10246 5. Remove the multi-function switch. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Locations > Page 10250 Door/Trunk Ajar Indicator/Lamp: Description and Operation The DOOR AJAR indicator illuminates when any of the vehicle doors are open. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 10254 Door Switch: Service and Repair REMOVAL 1. Remove the door trim panel. 2. Remove the door latch. For additional information, refer to Door Latch. 3. Remove the door opening warning lamp switch. 1 Lift the locking tab. 2 Rotate the door opening warning lamp switch counterclockwise. 3 Remove the door opening warning lamp switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10259 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10260 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10261 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10262 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10263 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10264 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10265 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10266 Driver/Vehicle Information Display: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10267 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10268 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10269 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10270 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10271 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10272 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10273 Driver/Vehicle Information Display: Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10274 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10275 Driver/Vehicle Information Display: Electrical Diagrams Diagram 69-1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10276 Diagram 69-2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > System Description Driver/Vehicle Information Display: Description and Operation System Description The message center system consists of: - message center switch module - message center indicator Message Center Switch Module The message center switch module has seven switches and is located below the message center indicator in the center console. The message center switches are: ENGLISH/METRIC mode - fuel computer (FUEL) RANGE - STATUS - economy (ECON) - RESET - system check and warnings (SYSTEM CHECK) - OIL CHANGE RESET Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > System Description > Page 10279 Driver/Vehicle Information Display: Description and Operation Principles of Operation (How Does It Work ?) Display Dimming The dimming of the indicator display is controlled by the pulse width dimmer module. The voltage on Pin 2 controls the brightness of the message center display. When the exterior lamps are off, this voltage will be zero volts and the message center display will be at maximum brightness. When the exterior lamps are on, this voltage will be controlled by the pulse width dimmer module and will be between 2.5 volts and battery voltage. The message center display will be brighter as this voltage approaches battery voltage. If there is a warning on the message center display, the display will not dim to its lowest level. When the headlamps or parking lamps are OFF, the display of the message center indicator will be maximum brightness and the labels for the center five switches of the message center switch module will not be illuminated. When the head lamps or parking lamps are ON, the brightness of the display of the message center indicator and the labels for the center five switches of the message center switch module will be controlled by the pulse width dimmer module. English/Metric Mode The ENGLISH/METRIC switch controls the display mode for both the message center indicator and the electronic automatic temperature control. A press of the ENGLISH/METRIC switch will change both displays between english mode and metric mode. Vehicle Speed Signal The vehicle speed signal is generated by the rear anti-lock brake sensor and sent to the 4-wheel Anti-lock Brake System (4WABS) module. The 4WABS module sends the vehicle speed signal via circuit 679 (GY/BK) to all systems which require a vehicle speed signal input. Fuel Computer - Range The RANGE feature has two displays: the distance that can be traveled before refueling, and the distance that was traveled since the last trip odometer reset. The RANGE switch will change the message center indicator between the two displays. The RANGE (distance to empty) feature is calculated using the fuel flow signal from the Powertrain Control Module (PCM), the speed signal from the 4WABS module and the fuel level signal from the fuel level sender. The fuel flow and speed signals are used to calculate a Running Average Fuel Economy (RAFE), which is multiplied by the fuel remaining to give the range. RAFE is not the same number as the Average Fuel Economy displayed by the message center indicator. RAFE is based on the past driving history and can only be reset by disconnecting the battery. When the range decreases to 80 km (50 mile) to empty, the message center will display the LOW FUEL LEVEL warning. With a fuel tank full of fuel (160 ohm signal from fuel sender) and after a battery disconnect, the RANGE should be approximately 644 km (400 miles) to empty. The RANGE (trip odometer) feature is calculated using the speed signal from the 4WABS module. It can be reset to zero by pressing the reset switch while the trip odometer is displayed on the message center. Fuel Computer - Status The STATUS feature has two displays: Fuel-to-Empty and Fuel-Used. The STATUS switch will change the message center indicator between the two displays. The fuel-to-empty calculation is achieved using the fuel level signal from the fuel level sender. The fuel-used feature is calculated using the fuel flow signal from the PCM and can be reset to zero by pressing the RESET switch while the fuel-used feature is displayed on the message center. Fuel Computer - Economy The Economy (ECON) feature has two displays: average and instant. Depressing the ECON switch changes the message center indicator between both displays. The economy is calculated using the fuel flow signal from the powertrain control module and the speed signal from the 4WABS module. The average fuel economy feature can be reset by pressing the RESET switch while the average fuel economy feature is displayed on the message center indicator. System Check and Warnings Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > System Description > Page 10280 The SYSTEM CHECK feature cycles the message center indicator through a status of each system being monitored. For each of the monitored systems, the message center indicator will indicate either an OK message or a warning message for two seconds. - At normal conclusion of the system check sequence, the message center indicator will display all active warnings or the last feature displayed before entering the SYSTEM CHECK mode. - System warnings alert the driver to possible concerns or malfunctions in the vehicle operating systems. - There are 7 warning messages which can be displayed for two seconds by the message center indicator to show the status of the monitored systems. - When a warning occurs, the warning message is displayed and a one-second tone sounds. The warning message will appear at a brighter level if the message center indicator is dimmed. - In the event of a multiple warning situation, the message center indicator will cycle the display to show all warnings by displaying each warning message for four seconds. - To display the operator selectable features of the message center indicator while a warning is displayed, the warning message may be removed from the message center indicator display by pressing the RESET switch. The message center indicator will display the last selected feature if there are no more warning messages. - This allows operation of all functions of the message center indicator after pressing the RESET switch and clearing the warning message. Warning messages which have been reset will either reappear on the display in 10 minutes from the reset or will not reappear until an ignition switch OFF-RUN cycle. If warning messages reappear it is a reminder that these warning conditions still exist. Warnings may be repeatedly reset. All warning messages will reappear after an entire SYSTEM CHECK sequence has been completed. Charging System Warning (CHECK CHARGING SYSTEM) This warning message is displayed when the electrical system is not maintaining correct voltage at the message center indicator. There will be a few seconds delay before the warning is displayed or removed. Engine Coolant Temperature Warning (CHECK ENGINE TEMP) This warning message is displayed when the engine coolant is overheating. The message center indicator senses the voltage level on Circuit 39 (RD/WH) (to the message center indicator). If that voltage is greater than approximately 2.7 volts, at a battery voltage of 13.5 volts there will be no warning. If it is less than approximately 2.7 volts, at a battery voltage of 13.5 volts then the warning will be displayed. The message center indicator filters this input; therefore, there will be a few seconds delay before the warning is displayed or removed. Fuel Level Warning (LOW FUEL LEVEL) This warning message is displayed when there is approximately 80 km (50 mile) or less left before the vehicle runs out of fuel. Oil Level Warning (LOW OIL LEVEL) This warning message is displayed when the engine oil level is low. When the engine oil level is normal, the input to the message center indicator will be an open circuit. When the engine oil level is low, the low oil level sensor will close, grounding the input to the message center indicator and the warning will be displayed during the next ignition cycle of OFF to RUN. This low oil level sensor is only monitored when the ignition switch is OFF. There is a delay of up to 12 minutes in this monitoring in order to allow the oil to drain back into the oil pan and reach the correct level. Oil Life Warning (CHANGE OIL SOON or OIL CHANGE REQUIRED) If the connection to the oil temperature sensor is open circuit or shorted, the message center display will read OIL TEMP SIGNAL ERROR instead of displaying the PERCENTAGE OIL LIFE LEFT during system cheek sequence. One of these warning messages is displayed when the engine oil life remaining is five percent or less. When oil life left is between five percent and zero percent, the "CHANGE OIL SOON" message will be displayed. - When oil life left reaches zero percent, the "OIL CHANGE REQUIRED" message will be displayed. The message center indicator will indicate the percent of oil life remaining during System Check. This percentage is based on the driving history and the time since the last oil change. In order to ensure accurate oil life left indications, the driver should only carry out the OIL CHANGE RESET procedure, as described in the Owner's Guide, after an oil change. To calculate the percentage of oil life remaining, the oil life feature uses: oil temperature sensor input - tachometer input from the PCM - vehicle speed signal input - clock time (maintained internally by the message center) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > System Description > Page 10281 - The oil life will decrease from 100 percent to 0 percent in no more than 12,070 km (7,500 mile) or 6 months. It will reach zero percent sooner under different driving conditions. - The percentage of oil life remaining is the second display in the system check sequence. - When oil life remaining is between five percent and zero percent, the "CHANGE OIL SOON" message will be displayed. - When oil life left reaches zero percent, the "OIL CHANGE REQUIRED" message will be displayed. Washer Fluid Level Warning (LOW WASHER FLUID) This warning message is displayed when there is less than one quarter of the container of washer fluid remaining When the washer fluid level is normal, the windshield washer reservoir fluid level sensor will close, grounding the input Circuit 82 (PK/YE) at C200931 of the message center indicator. - When the washer fluid level is low, the input to the message center indicator will be open and the warning will be displayed. The message center indicator filters this input therefore, there will be a 20-second delay before the warning is displayed or removed. Warning Chime A short warning chime (0.1 second) is output with every message center switch press. A longer warning chime (1.0 second) is output when a new warning first appears on the message center indicator display. To activate the warning, the message center pulls the chime request output below one volt during the length of the tone. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Page 10282 Driver/Vehicle Information Display: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is part of, please refer to Instrument Panel, Gauges and Warning indicators; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Message Center Assembly Driver/Vehicle Information Display: Service and Repair Message Center Assembly REMOVAL 1. Remove the message center console. Grasp the front of the console and lift upward. 2. Disconnect the electrical connectors from the message center indicator. 3. Remove the screws retaining the message center indicator. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Message Center Assembly > Page 10285 Driver/Vehicle Information Display: Service and Repair Message Center Assembly Switch REMOVAL 1. Remove the message center indicator. Refer to Driver/Vehicle Information Display. 2. Disconnect the electrical connector. 3. Remove the message center switch module screws and remove the module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Page 10286 73 Digital Multimeter Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Fuel Gauge Module > Component Information > Description and Operation Fuel Gauge Module: Description and Operation NOTE: - The fuel gauge and instrument cluster gauge amplifier must be replaced as a set. The fuel gauge and instrument cluster gauge amplifier are calibrated together. - If the ignition key is left in the ON position during fueling, a slow to respond fuel gauge indication may result. The ignition key must be placed in the OFF position during or after refueling for accurate fuel gauge indication. The instrument cluster gauge amplifier electrically averages the fuel sender readings so the gauge displays the actual fuel level and not the fluctuations due to fuel sloshing. The amplifier also supplies the signal to illuminate the CHECK GAGE indicator to indicate low fuel, high engine coolant temperature, or low engine oil pressure. The gauge amplifier is a small printed circuit board located in a pocket on the back of the instrument cluster. The electrical connections are made with a spring-type connector. There are no provisions for calibration or adjustment. The fuel gauge and the instrument cluster gauge amplifier must be replaced as a unit. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Fuel Gauge Module > Component Information > Description and Operation > Page 10294 Fuel Gauge Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Fuel Gauge Module > Component Information > Description and Operation > Page 10295 Fuel Gauge Module: Service and Repair Service and Repair The fuel gauge and instrument cluster gauge amplifier (Slosh Module) are calibrated together and must be replaced as a set. For further information regarding this component please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Testing and Inspection Fuel Gauge Sender: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Testing and Inspection > Page 10299 Fuel Gauge Sender: Service and Repair Service and Repair For further information regarding this component please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING:To reduce the risk of personal injury, do not use any memory saver devices. NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove the restraints control module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram See: Restraint Systems/Air Bag Systems. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable (14301) and wait at least one minute. For additional information, refer to See: Starting and Charging/Battery. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Disarming and Arming > Page 10305 7. Remove the two steering wheel back cover plugs. 8. Remove the two driver air bag module retaining bolts. 9. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module. 10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical connector at the clockspring. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Disarming and Arming > Page 10306 11. Open the glove compartment door to access the passenger air bag module mounting screws. 12. Remove the two screws. 13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Reaching one hand into the glove box opening, push out on the passenger air bag module and separate it from the instrument panel. 14. Disconnect the electrical connector and remove the passenger air bag module. 15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the passenger air bag module electrical connector. Vehicles equipped with seat side air bags Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Disarming and Arming > Page 10307 16. Disconnect the passenger seat side air bag module electrical connector located under the passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector located under the driver seat. 19. Connect the restraint system diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical connector. All vehicles 20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground cable. Reactivation Procedure All vehicles 1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles equipped with seat side air bags 3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side air bag module electrical connector located under the driver seat. 4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint system diagnostic tool from the body harness side of the passenger seat side air bag module electrical connector located under the passenger seat. 6. Connect the passenger seat side air bag module electrical connector All vehicles 7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air bag module electrical connector. 8. Install the passenger air bag module. 9. Connect the passenger air bag module electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Disarming and Arming > Page 10308 10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical connector at the clockspring. 11. Position the driver air bag module to the steering wheel. 1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag module to the steering wheel. 12. Install the two driver air bag module retaining bolts. 13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON. 15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 17. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Disarming and Arming > Page 10309 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern: 1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle battery connected? Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 Disarming and Arming > Page 10310 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure Prove out the system means to turn the ignition switch from the OFF to the RUN position and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag Supplemental Restraint System (SRS) fault is present, the air bag indicator will either: ^ fail to light. ^ remain lit continuously. ^ flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the RUN position. This is the time required for the Restraints Control Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Map Lamp > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Circuit Board > Component Information > Description and Operation Instrument Panel Circuit Board: Description and Operation The instrument cluster printed circuit is a flexible circuit that supplies power and ground to the instrument cluster indicators and gauges. It is constructed of copper foil bonded to a polyester base film (usually referred to as Mylar). Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Circuit Board > Component Information > Description and Operation > Page 10318 Instrument Panel Circuit Board: Service and Repair REMOVAL WARNING: ILLUMINATION BULBS ARE PRESSURIZED AND MAY SHATTER IF IMPROPERLY HANDLED. WEAR EYE PROTECTION WHEN REPLACING ILLUMINATION BULBS. CAUTION: If gauges are being removed from the cluster assembly, do not remove the gauge pointers. Magnetic gauges cannot be recalibrated. 1. Remove the instrument cluster; refer to Instrument Panel. 2. Remove the illumination and indicator bulbs; refer to Warning Indicator Bulb. 3. Remove the gauges; refer to Gauges. 4. Remove the nineteen instrument gauge clips. NOTE: Do not reuse instrument gauge clips. 5. Remove the instrument cluster printed circuit. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Locations > Page 10322 Instrument Panel Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Locations > Page 10323 Instrument Panel Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Locations > Page 10324 Instrument Panel Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Panel Illumination Control Module > Component Information > Locations Panel Illumination Control Module: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Panel Illumination Control Module > Component Information > Locations > Page 10328 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Panel Illumination Control Module > Component Information > Locations > Page 10329 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Panel Illumination Control Module > Component Information > Locations > Page 10330 Panel Illumination Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Panel Illumination Control Module > Component Information > Locations > Page 10331 Panel Illumination Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Panel Illumination Control Module > Component Information > Locations > Page 10332 Panel Illumination Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Service and Repair Key Reminder Switch: Service and Repair For further information regarding the service of this component and the system that it is part of, please refer to Instrument Panel, Gauges and Warning indicators; Service and Repair; Warning Devices. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation > Instrument Cluster Low Fuel Lamp/Indicator: Description and Operation Instrument Cluster NOTE: - The fuel gauge and instrument cluster gauge amplifier must be replaced as a set. The fuel gauge and instrument cluster gauge amplifier are calibrated together. - If the ignition key is left in the ON position during fueling, a slow to respond fuel gauge indication may result. The ignition key must be placed in the OFF position during or after refueling for accurate fuel gauge indication. The instrument cluster gauge amplifier electrically averages the fuel sender readings so the gauge displays the actual fuel level and not the fluctuations due to fuel sloshing. When the fuel level drops to a predetermined level, the CHECK GAGE indicator will illuminate. The amplifier also supplies the signal to illuminate the CHECK GAGE indicator to indicate low fuel, high engine coolant temperature, or low engine oil pressure. The gauge amplifier is a small printed circuit board located in a pocket on the back of the instrument cluster. The electrical connections are made with a spring-type connector. There are no provisions for calibration or adjustment. The fuel gauge and the instrument cluster gauge amplifier must be replaced as a unit. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation > Instrument Cluster > Page 10340 Low Fuel Lamp/Indicator: Description and Operation Information and Message Center This warning message is displayed when there is approximately 80 km (50 miles) or less left before the vehicle runs out of fuel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation > Page 10341 Low Fuel Lamp/Indicator: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Locations > Page 10345 Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) Malfunction Indicator Lamp (MIL) Check Engine, Service Engine Soon Or ISO Standard Engine Symbol The Malfunction Indicator Lamp (MIL) (Figure 15) alerts the driver that the Powertrain Control Module (PCM) has detected an OBD II emission-related component or system fault. When this occurs, an OBD II Diagnostic Trouble Code (DTC) will be set. ^ The MIL is located on the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or ISO standard engine symbol (Figure 16). ^ Power is supplied to the MIL whenever the ignition switch is in the RUN or START position. ^ The MIL will remain on in the RUN/START mode as a bulb check during the instrument cluster proveout for approximately 4 seconds. ^ If the MIL remains on after the bulb check: The PCM illuminates the MIL for an emission related concern and a DTC will be present. - The instrument cluster will illuminate the MIL if the PCM does not send a control message to the instrument cluster. - The PCM is operating in the Hardware Limited Operation Strategy (HLOS). - The MIL circuit is shorted to ground. ^ If the MIL remains off (during the bulb check): Bulb is damaged. - MIL circuit is open. ^ To turn off the MIL after a repair, a reset command from the Scan Tool must be sent, or three consecutive drive cycles must be completed without a fault. ^ For any MIL concern, GO to Computers and Control Systems/Testing and Inspection. ^ If the MIL blinks at a steady rate, a severe misfire condition could possibly exist. ^ If the MIL blinks erratically, an intermittent open B+ to the bulb or an intermittent short to ground in the MIL circuit exist. Also, the PCM can reset while cranking if battery voltage is low. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation Odometer: Description and Operation A million-mile tamper-resistant odometer is standard. Replacement speedometers have an odometer that can be reset to indicate correct vehicle mileage. NOTE: Some state laws require that the odometer in any replacement speedometer must register the same as on the removed odometer. Replacement speedometers and odometer modules with the mileage preset are available through Ford electronic repair centers. If the actual vehicle mileage cannot be determined, the repair centers are able to supply odometers set to "0" miles. An odometer mileage sticker is supplied with the replacement odometer. This sticker must display the estimated vehicle mileage and be affixed to the driver door jamb. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation > Page 10349 Odometer: Testing and Inspection To test the odometer accuracy, drive the vehicle over a measured distance of at least 16 consecutive kilometers (10 mile). Check measured distance against odometer measured distance. Acceptable odometer measured distance is 15.5 - 16.7 km (9.6 - 10.4 mile). For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation Oil Change Reminder Lamp: Description and Operation If the connection to the oil temperature sensor is open circuit or shorted, the message center display will read OIL TEMP SIGNAL ERROR instead of displaying the PERCENTAGE OIL LIFE LEFT during system cheek sequence. One of these warning messages is displayed when the engine oil life remaining is five percent or less. - When oil life left is between five percent and zero percent, the "CHANGE OIL SOON" message will be displayed. - When oil life left reaches zero percent, the "OIL CHANGE REQUIRED" message will be displayed. The message center indicator will indicate the percent of oil life remaining during System Check. This percentage is based on the driving history and the time since the last oil change. In order to ensure accurate oil life left indications, the driver should only carry out the OIL CHANGE RESET procedure, as described in the Owner's Guide, after an oil change. To calculate the percentage of oil life remaining, the oil life feature uses: - oil temperature sensor input - tachometer input from the PCM - vehicle speed signal input - clock time (maintained internally by the message center) - The oil life will decrease from 100 percent to 0 percent in no more than 12,070 km (7,500 mile) or 6 months. It will reach zero percent sooner under different driving conditions. - The percentage of oil life remaining is the second display in the system check sequence. - When oil life remaining is between five percent and zero percent, the "CHANGE OIL SOON" message will be displayed. - When oil life left reaches zero percent, the "OIL CHANGE REQUIRED" message will be displayed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation > Page 10353 Oil Change Reminder Lamp: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Description and Operation > Page 10354 Oil Change Reminder Lamp: Service and Repair Oil Change Reset Press the OIL CHANGE RESET control to reset the oil life feature to 100% (or your personalized oil reset percentage) (at optimal driving conditions, 100% oil life is equivalent to a maximum of 12,000 kilometers [7,500 miles]). After you have the oil changed, you must press and hold the OIL CHANGE RESET control for five seconds. The message center will count down for five seconds. After a successful reset, the message center will display OIL LIFE RESET TO 100%. (If you have established a personalized oil reset percentage, the display will show that percentage instead of 100%.) This reset procedure should be performed only after an oil change to ensure accurate oil life indications. Your personalized oil reset percentage allows you to establish a smaller oil change interval than the manufacturer's recommended interval. To establish your personalized oil reset percentage: 1. Press and hold the OIL CHANGE RESET control and press the RESET control while the display is still counting gown the five seconds to reset. The display will change to START OIL LIFE AT XXX%. 2. Press the OIL CHANGE RESET control until the displayed percentage is the personalized oil reset percentage you desire. Your choices are 100%, 90%, 80%, 70%, 60%, 50% 40% and 30%. 3. Press the RESET control to complete the procedure. Pressing any control other than RESET of OIL CHANGE RESET will abort this procedure and will not establish your new personalized oil reset percentage. When your personalized oil reset percentage has been established, it will be used beginning with the completion of your next OIL CHANGE RESET procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 This warning message is displayed when the engine oil level is low. When the engine oil level is normal, the input to the message center indicator will be an open circuit. When the engine oil level is low, the low oil level sensor will close, grounding the input to the message center indicator and the warning will be displayed during the next ignition cycle of OFF to RUN. This low oil level sensor is only monitored when the ignition switch is OFF. There is a delay of up to 12 minutes in this monitoring in order to allow the oil to drain back into the oil pan and reach the correct level. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Locations > Page 10361 Oil Pressure Gauge: Testing and Inspection Magnetic Gauge Testing The Instrument Gauge System Tester is used to diagnose concerns with the instrument cluster magnetic gauges. To test the magnetic gauges: ^ Disconnect the connector from the appropriate sender and connect the signal wire to the Instrument Gauge System Tester. ^ Turn the vehicle ignition switch lock cylinder to the ON position. With Instrument Gauge System Tester attached to the oil pressure switch connector and the ignition switch lock cylinder in the RUN position (engine not running), set Instrument Gauge System Tester to infinite resistance. The center line of the pointer should fall on or below the "L" mark. Short the connector directly to engine ground. The centerline of the pointer should fall slightly above mid-scale. ^ If the oil pressure gauge tests within calibration, install a new oil pressure switch. ^ If the oil pressure gauge still tests out of calibration, install a new gauge. For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil pressure sensor 9-11 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications > Page 10365 Oil Pressure Sender: Description and Operation The oil pressure switch is installed in the engine block and consists of a diaphragm and contact points. The contact points are closed with oil pressure causing the gauge to indicate NORMAL oil pressure. With no oil pressure, the contacts open and the gauge indicates low oil pressure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications > Page 10366 Oil Pressure Sender: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Additional information may also be found at Engine; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications > Page 10367 Oil Pressure Sender: Service and Repair Removal and Installation 1. Discard the battery ground cable. 2. Disconnect the oil pressure sensor electrical connector and remove the sensor. 3. Note: Coat the threads of the oil pressure sensor with Pipe Sealant with Teflon D8AZ-19554-A or Wsk-M2G350-A2. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Locations > Page 10372 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Locations > Page 10376 Overdrive Indicator Lamp: Description and Operation Overdrive (O/D) Off The O/D OFF indicator illuminates when the transmission is locked out of O/D. This dual function indicator will also flash off and on if a transmission malfunction is detected. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator > Component Information > Service and Repair Parking Assist Warning Indicator: Service and Repair REMOVAL 1. Remove the LH quarter trim panel. 2. Remove the parking aid speaker. 1 Disconnect the electrical connector. 2 Remove the pin-type retainers. 3 Remove the parking aid speaker. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device Control Module: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10386 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10387 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10388 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10389 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10390 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10391 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10392 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10393 Audible Warning Device Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10394 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10395 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10396 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10397 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10398 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10399 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 10400 Audible Warning Device Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 10401 Audible Warning Device Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 10402 Audible Warning Device Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Fuel Gauge Module > Component Information > Description and Operation Fuel Gauge Module: Description and Operation NOTE: - The fuel gauge and instrument cluster gauge amplifier must be replaced as a set. The fuel gauge and instrument cluster gauge amplifier are calibrated together. - If the ignition key is left in the ON position during fueling, a slow to respond fuel gauge indication may result. The ignition key must be placed in the OFF position during or after refueling for accurate fuel gauge indication. The instrument cluster gauge amplifier electrically averages the fuel sender readings so the gauge displays the actual fuel level and not the fluctuations due to fuel sloshing. The amplifier also supplies the signal to illuminate the CHECK GAGE indicator to indicate low fuel, high engine coolant temperature, or low engine oil pressure. The gauge amplifier is a small printed circuit board located in a pocket on the back of the instrument cluster. The electrical connections are made with a spring-type connector. There are no provisions for calibration or adjustment. The fuel gauge and the instrument cluster gauge amplifier must be replaced as a unit. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Fuel Gauge Module > Component Information > Description and Operation > Page 10406 Fuel Gauge Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Fuel Gauge Module > Component Information > Description and Operation > Page 10407 Fuel Gauge Module: Service and Repair Service and Repair The fuel gauge and instrument cluster gauge amplifier (Slosh Module) are calibrated together and must be replaced as a set. For further information regarding this component please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Locations > Page 10411 Instrument Panel Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Locations > Page 10412 Instrument Panel Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Locations > Page 10413 Instrument Panel Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations Panel Illumination Control Module: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations > Page 10417 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations > Page 10418 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations > Page 10419 Panel Illumination Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations > Page 10420 Panel Illumination Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Locations > Page 10421 Panel Illumination Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Locations > Page 10425 Seat Belt Reminder Lamp: Description and Operation The safety belt warning indicator is powered through the GEM/CTM module. When the ignition key is turned on, the indicator illuminates for four to eight seconds even if the safety belt is buckled. For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Locations > Page 10426 Seat Belt Reminder Lamp: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the upper and lower steering column shrouds. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair > Page 10431 5. Remove the multi-function switch. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 10435 Door Switch: Service and Repair REMOVAL 1. Remove the door trim panel. 2. Remove the door latch. For additional information, refer to Door Latch. 3. Remove the door opening warning lamp switch. 1 Lift the locking tab. 2 Rotate the door opening warning lamp switch counterclockwise. 3 Remove the door opening warning lamp switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection Fuel Gauge Sender: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Page 10439 Fuel Gauge Sender: Service and Repair Service and Repair For further information regarding this component please refer to Instrument Panel, Gauges and Warning Indicators; Service and Repair. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Service and Repair Key Reminder Switch: Service and Repair For further information regarding the service of this component and the system that it is part of, please refer to Instrument Panel, Gauges and Warning indicators; Service and Repair; Warning Devices. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations > Page 10446 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Locations > Page 10450 Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the gearshift lever in the (D) position. - Rotate the gearshift lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (D) position). 3. Hang a 3.6 kg (8 lb.) weight on the gearshift lever. 4. Center the pointer in the middle of the (D) position. - Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer. 5. Remove the 3.6 kg (8 lb.) weight. 6. Carefully move the gearshift lever from detent to detent and compare with the transmission settings. - Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Locations > Page 10454 Speedometer Head: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Locations > Page 10458 Tachometer: Description and Operation The tachometer is a 6000 rpm tachometer. It has four terminals: one labeled B (12 to 1 4.5V), one labeled S (EDIS tach signal in), and two labeled G (cylinder selection grounds). The bottom ground (G) terminal is grounded. The top ground (G) terminal is grounded through a 4.32 kohm resistor in a 6-cylinder engine vehicle and is connected directly to ground for an 8-cylinder engine vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Locations > Page 10459 Tachometer: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Locations > Page 10463 Temperature Gauge: Testing and Inspection Magnetic Gauge Testing The Instrument Gauge System Tester is used to diagnose concerns with the instrument cluster magnetic gauges. To test the magnetic gauges: ^ Disconnect the connector from the appropriate sender and connect the signal wire to the Instrument Gauge System Tester. ^ Turn the vehicle ignition switch lock cylinder to the ON position. 1. Disconnect water temperature indicator sender unit C104. Connect one lead of Instrument Gauge System Tester to water temperature indicator sender unit C104, circuit 39 (RD/WH), and the other lead to ground. 2. Set Instrument Gauge System Tester to 300 ohms. Key ON. Wait one minute. The engine coolant temperature gauge should indicate C (cold). Key OFF. 3. Set Instrument Gauge System Tester to 45 ohms. Key ON. Wait one minute. The engine coolant temperature gauge pointer should be in the one quarter range to mid range. Key OFF. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Locations > Page 10464 4. Set Instrument Gauge System Tester to 18 ohms. Key ON. Wait one minute. The engine coolant temperature gauge should indicate H (hot). Key OFF. For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. See: Testing and Inspection/Instrument Cluster/Pinpoint Tests Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Engine coolant temperature (ECT) sensor 89 in.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Specifications > Page 10468 Temperature Sensor (Gauge): Description and Operation When the engine temperature is low, the resistance of the water temperature indicator sender unit is high, thus restricting the flow of current through the gauge and moving the pointer only a short distance. As the temperature of the coolant increases, the resistance decreases, allowing more current to flow through the gauge and results in a corresponding movement of the pointer. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation Temperature Warning Lamp/Indicator: Description and Operation This warning message is displayed when the engine coolant is overheating. The message center indicator senses the voltage level on Circuit 39 (RD/WH) (to the message center indicator). If that voltage is greater than approximately 2.7 volts, at a battery voltage of 13.5 volts there will be no warning. If it is less than approximately 2.7 volts , at a battery voltage of 13.5 volts then the warning will be displayed. The message center indicator filters this input; therefore, there will be a few seconds delay before the warning is displayed or removed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation TRANSMISSION CONTROL INDICATOR LAMP The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to Transmission Control Switch, PCM Inputs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 10482 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Specifications Backup Lamp Switch: Specifications Backup Lamp Switch 25-35 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Specifications > Page 10487 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Specifications > Page 10488 Backup Lamp Switch: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Specifications > Page 10489 Backup Lamp Switch: Service and Repair REMOVAL 1. Raise and support the vehicle; refer to Maintenance/Service and Repair. 2. Disconnect the backup lamp switch electrical connector. 3. Remove the backup lamp switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Brake Lamp: Customer Interest A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 10498 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Brake Lamp: All Technical Service Bulletins A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 10504 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Brake 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10507 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10508 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10509 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10510 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10511 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10512 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10513 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10514 Brake Lamp: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10515 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10516 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10517 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10518 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10519 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10520 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10521 Brake Lamp: Electrical Diagrams For further information regarding this component please refer to : Lighting and Horns/Diagrams. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Brake Lamp: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the stoplamps. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART 3. If the fault is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10524 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10525 Brake Lamp: Pinpoint Tests J1 - J2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10526 J3 - J4 Test K: One or More Stoplamps Are Inoperative Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10527 K1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10528 K2 - K3 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10529 K4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Page 10530 73 Digital Multimeter Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Locations Exterior Lighting System Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Locations > Page 10534 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Locations > Page 10535 Brake Pedal Position Switch: Description and Operation BRAKE PEDAL POSITION SWITCH Typical Brake Pedal Position Switch The Brake Pedal Position (BPP) switch (Figure 21) is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality. On most applications the BPP switch is hard wired to the PCM and supplies battery positive voltage (B+) when the vehicle brake pedal is applied. On other applications the BPP switch signal is broadcast over the SCP link via another module to be received by the PCM. On applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stop amp bulbs has failed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Locations > Page 10536 Brake Pedal Position Switch: Service and Repair REMOVAL 1. Disconnect the brake pedal position (BPP) switch connector. 2. Remove the BPP switch 1 Remove the self-locking pin. 2 Remove the spacer. 3 Remove the BPP switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Service and Repair Cargo Lamp: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the lamp assembly. 1 Use a thin bladed tool to carefully pry the lamp assembly to the left. 2 Press the locking tab inward. 3 Lower the lamp assembly. 4 Disconnect electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Center Mounted Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Center Mounted Brake Lamp: Customer Interest A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Center Mounted Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 10548 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Mounted Brake Lamp: > 02-17-6 > Sep > 02 > A/T Inadvertent Shift Interlock Disabling Center Mounted Brake Lamp: All Technical Service Bulletins A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Mounted Brake Lamp: > 02-17-6 > Sep > 02 > A/T Inadvertent Shift Interlock Disabling > Page 10554 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > Page 10555 Center Mounted Brake Lamp: Specifications High Mounted Stoplamp Nuts 2.7-3.7 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > Page 10556 Exterior Lighting System Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > Page 10557 Center Mounted Brake Lamp: Service and Repair REMOVAL 1. Remove the liftgate glass. Refer to Windows. 2. Remove the plugs. 3. Remove the nuts. 4. Remove the high-mounted stoplamp. 1 Disconnect the electrical connector. 2 Remove the high-mounted stoplamp. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Interior Light Switch > Component Information > Service and Repair Interior Light Switch: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the interior lamp switch. 1 Disconnect the interior lamp switch electrical connector. 2 Remove the interior lamp switch. ^ Push inward; rotate counterclockwise. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Specifications Daytime Running Lamp Control Unit: Specifications Daytime Running Lamps Control Module Bolts 3 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 10566 Daytime Running Lamp Control Unit: Locations Left front corner of engine. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 10567 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 10568 Daytime Running Lamp Control Unit: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the daytime running lamps (DRL) control module. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the DRL control module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Service and Repair Dimmer Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the upper and lower steering column shrouds. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Service and Repair > Page 10572 5. Remove the multi-function switch. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations Battery Discharge Protection Relay: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 10576 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 10577 Battery Discharge Protection Relay: Description and Operation The following components are under the control of the battery saver relay: ^ Delayed accessory relay. ^ Overhead interior lamp with map lamps. ^ Overhead interior lamp switch. ^ Interior lamp relay coil. The battery saver relay becomes active (relay coil is energized) when the GEM is in the awake mode, and is deactivated (relay coil is de-energized) when the GEM is in the sleep mode. The battery saver will remain active until the ignition state is not ACC or RUN and 45 minutes have passed since the last active input. At that time, the relay will be deactivated and power to the above circuits will terminate. Five minutes after the battery saver relay has become deactivated, the GEM will go into a lower power state known as sleep mode. In the sleep mode, the GEM will deactivate all outputs and will monitor only select inputs. Logical characteristics of the GEM battery saver mode are as follows: Feature Input: ^ Sleep/awake mode status. Feature Output: ^ Battery saver relay control (open circuit in sleep mode, grounded when awake). For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 10578 Battery Discharge Protection Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 10579 Battery Discharge Protection Relay: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Rear Domelamp Assembly Dome Lamp: Service and Repair Rear Domelamp Assembly REMOVAL 1. Disconnect the battery ground cable. 2. Remove the lamp assembly. 1 Use a thin bladed tool to carefully pry the lamp assembly to the left. 2 Press the locking tab inward. 3 Lower the lamp assembly. 4 Disconnect electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Rear Domelamp Assembly > Page 10584 Dome Lamp: Service and Repair Front Domelamp Assembly REMOVAL 1. Disconnect the battery ground cable. 2. Use a thin bladed tool to carefully pry the dome lamp lens out. ^ Replace the bulb if necessary. 3. Remove the screws and lower the lamp assembly. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 10588 Door Switch: Service and Repair REMOVAL 1. Remove the door trim panel. 2. Remove the door latch. For additional information, refer to Door Latch. 3. Remove the door opening warning lamp switch. 1 Lift the locking tab. 2 Rotate the door opening warning lamp switch counterclockwise. 3 Remove the door opening warning lamp switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Locations > Page 10592 Exterior Lighting Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Locations > Page 10593 Exterior Lighting Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Locations > Page 10594 Exterior Lighting Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 10599 Fog/Driving Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Specifications Fog/Driving Lamp Switch: Specifications Fog Lamp Switch Mounting Bezel Screws 2-3 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Specifications > Page 10603 Exterior Lighting System Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Specifications > Page 10604 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Specifications > Page 10605 Fog/Driving Lamp Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. 3 Disconnect the electrical connectors. 3. Remove the fog lamp switch. 1 Remove the screws. 2 Remove the mounting bezel. 3 Release the two tabs and remove the fog lamp switch. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Specifications > Page 10606 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 10611 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 10615 Hazard Warning Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 10616 Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 10617 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 10618 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service Precautions Headlamp Bulb: Service Precautions WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. HANDLE THE BULB CAREFULLY. GRASP THE BULB ONLY BY ITS BASE. AVOID TOUCHING THE GLASS ENVELOPE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service Precautions > Page 10623 Headlamp Bulb: Service and Repair REMOVAL WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. HANDLE THE BULB CAREFULLY. GRASP THE BULB ONLY BY ITS BASE. AVOID TOUCHING THE GLASS ENVELOPE. NOTE: The headlamp bulb should not be removed from the headlamp until just before a replacement bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb performance. Contaminants may enter the headlamp where they can settle on the lens and reflector. Never turn the headlamps on with the bulb removed. 1. Remove the headlamp assembly. 2. Rotate the headlamp bulb retainer counterclockwise and remove. 3. Remove the headlamp bulb. INSTALLATION 1. To install, reverse the removal procedure. WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. HANDLE THE BULB CAREFULLY. GRASP THE BULB ONLY BY ITS BASE. AVOID TOUCHING THE GLASS ENVELOPE. NOTE: ^ Never turn the head lamps on with the bulb removed. ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Relay > Component Information > Locations > Page 10627 Headlamp Dimmer Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams Headlamp Dimmer Switch: Diagrams For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 10631 Headlamp Dimmer Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 10632 Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 10633 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 10634 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 10638 Headlamp Relay: Testing and Inspection Testing an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper wires and 73 Digital Multimeter. Remove the relay to be tested from the power distribution box, fuse junction panel or individual connector. Terminals Component Testing Procedure Schematic Use 73 Digital Multimeter to check for continuity between terminal 2 and all other terminals. If resistance is 5 ohms or less between terminal 2 and any Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 10639 other terminal, replace the relay. If resistance is greater than 5 ohms, continue the test. Use two jumper wires to connect relay terminals 1 and 3 directly to the positive battery terminal. Set 73 Digital Multimeter in volts position and check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect the third jumper wire to terminal 2, and ground the jumper wire to chassis ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Specifications Headlamp Switch: Specifications Head Lamp Switch Screws 2-3 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Specifications > Page 10643 Exterior Lighting System Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10646 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10647 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10648 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10649 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10650 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10651 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10652 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10653 Headlamp Switch: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10654 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10655 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10656 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10657 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10658 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10659 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10660 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 10661 Headlamp Switch: Testing and Inspection Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 10662 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 10663 Headlamp Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel steering column opening cover reinforcement; refer to Dashboard. 3. Remove the center instrument panel finish panel. 1 Remove the screws. 2 Remove the instrument panel finish panel. 4. Remove the instrument cluster finish panel. 1 Remove the screws. 2 Remove the cluster instrument panel finish panel. 5. Disconnect the headlamp switch electrical connectors and remove the headlamp switch knob. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 10664 6. Remove the headlamp switch. 1 Remove the screws. 2 Remove the headlamp switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 10669 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 10670 Horn Relay: Testing and Inspection Terminals Component Testing Procedure Schematic Use 73 Digital Multimeter to check for continuity between terminal 2 and all other terminals. If resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue the test. Use two jumper wires to connect relay terminal 1 and terminal 3 directly to the positive battery terminal. Set 73 Digital Multimeter in the volts position and check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 2 and ground the jumper wire to a known good Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 10671 ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Description and Operation Horn Switch: Description and Operation The horn blow switches are underneath the driver side air bag module in the steering wheel. The switches are powered through the air bag sliding contact and ground through the steering column. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Description and Operation > Page 10675 Horn Switch: Service and Repair REMOVAL 1. Remove the driver side air bag; refer to Air Bag Systems. 2. Remove the switches. 1 Disconnect the horn wire (BK) from the switches. 2 Remove the attaching bolts from the switches and remove the switches. INSTALLATION 1. To install, reverse the removal procedure. ^ Prove out the air bag system; refer to Air Bag Systems. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions Interior Lighting Module: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10681 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10682 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10683 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10684 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10685 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10686 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10687 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10688 Interior Lighting Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10689 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10690 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10691 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10692 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10693 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10694 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Page 10695 Interior Lighting Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Page 10696 Interior Lighting Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Page 10697 Interior Lighting Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 10701 Interior Lighting Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions License Plate 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10706 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10707 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10708 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10709 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10710 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10711 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10712 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10713 License Plate Lamp: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10714 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10715 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10716 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10717 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10718 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10719 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10720 License Plate Lamp: Electrical Diagrams For further information regarding this component please refer to : Lighting and Horns/Diagrams. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 10721 License Plate Lamp: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Lighting and Horns; Parking Lamp; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions Marker 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10729 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10730 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10731 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10732 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10733 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10734 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10735 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10736 Marker Lamp: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10737 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10738 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10739 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10740 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10741 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10742 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10743 Marker Lamp: Electrical Diagrams For further information regarding this component please refer to : Lighting and Horns/Diagrams. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Relay Module Parking Lamp Relay is located in the relay module. Relay module is located behind center of I/P. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 10748 Parking Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations Battery Discharge Protection Relay: Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 10753 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 10754 Battery Discharge Protection Relay: Description and Operation The following components are under the control of the battery saver relay: ^ Delayed accessory relay. ^ Overhead interior lamp with map lamps. ^ Overhead interior lamp switch. ^ Interior lamp relay coil. The battery saver relay becomes active (relay coil is energized) when the GEM is in the awake mode, and is deactivated (relay coil is de-energized) when the GEM is in the sleep mode. The battery saver will remain active until the ignition state is not ACC or RUN and 45 minutes have passed since the last active input. At that time, the relay will be deactivated and power to the above circuits will terminate. Five minutes after the battery saver relay has become deactivated, the GEM will go into a lower power state known as sleep mode. In the sleep mode, the GEM will deactivate all outputs and will monitor only select inputs. Logical characteristics of the GEM battery saver mode are as follows: Feature Input: ^ Sleep/awake mode status. Feature Output: ^ Battery saver relay control (open circuit in sleep mode, grounded when awake). For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 10755 Battery Discharge Protection Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Locations > Page 10756 Battery Discharge Protection Relay: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications Daytime Running Lamp Control Unit: Specifications Daytime Running Lamps Control Module Bolts 3 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 10760 Daytime Running Lamp Control Unit: Locations Left front corner of engine. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 10761 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Specifications > Page 10762 Daytime Running Lamp Control Unit: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the daytime running lamps (DRL) control module. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the DRL control module. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Locations > Page 10766 Exterior Lighting Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Locations > Page 10767 Exterior Lighting Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Locations > Page 10768 Exterior Lighting Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 10772 Fog/Driving Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Dimmer Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Dimmer Relay > Component Information > Locations > Page 10776 Headlamp Dimmer Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 10780 Headlamp Relay: Testing and Inspection Testing an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper wires and 73 Digital Multimeter. Remove the relay to be tested from the power distribution box, fuse junction panel or individual connector. Terminals Component Testing Procedure Schematic Use 73 Digital Multimeter to check for continuity between terminal 2 and all other terminals. If resistance is 5 ohms or less between terminal 2 and any Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 10781 other terminal, replace the relay. If resistance is greater than 5 ohms, continue the test. Use two jumper wires to connect relay terminals 1 and 3 directly to the positive battery terminal. Set 73 Digital Multimeter in volts position and check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect the third jumper wire to terminal 2, and ground the jumper wire to chassis ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 10785 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 10786 Horn Relay: Testing and Inspection Terminals Component Testing Procedure Schematic Use 73 Digital Multimeter to check for continuity between terminal 2 and all other terminals. If resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue the test. Use two jumper wires to connect relay terminal 1 and terminal 3 directly to the positive battery terminal. Set 73 Digital Multimeter in the volts position and check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 2 and ground the jumper wire to a known good Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 10787 ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions Interior Lighting Module: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10793 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10794 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10795 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10796 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10797 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10798 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10799 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10800 Interior Lighting Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10801 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10802 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10803 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10804 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10805 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10806 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Page 10807 Interior Lighting Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Page 10808 Interior Lighting Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Page 10809 Interior Lighting Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 10813 Interior Lighting Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Relay Module Parking Lamp Relay is located in the relay module. Relay module is located behind center of I/P. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 10817 Parking Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 10825 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Specifications Backup Lamp Switch: Specifications Backup Lamp Switch 25-35 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Specifications > Page 10829 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Specifications > Page 10830 Backup Lamp Switch: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Specifications > Page 10831 Backup Lamp Switch: Service and Repair REMOVAL 1. Raise and support the vehicle; refer to Maintenance/Service and Repair. 2. Disconnect the backup lamp switch electrical connector. 3. Remove the backup lamp switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Locations Exterior Lighting System Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Locations > Page 10835 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Locations > Page 10836 Brake Pedal Position Switch: Description and Operation BRAKE PEDAL POSITION SWITCH Typical Brake Pedal Position Switch The Brake Pedal Position (BPP) switch (Figure 21) is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality. On most applications the BPP switch is hard wired to the PCM and supplies battery positive voltage (B+) when the vehicle brake pedal is applied. On other applications the BPP switch signal is broadcast over the SCP link via another module to be received by the PCM. On applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stop amp bulbs has failed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component Information > Locations > Page 10837 Brake Pedal Position Switch: Service and Repair REMOVAL 1. Disconnect the brake pedal position (BPP) switch connector. 2. Remove the BPP switch 1 Remove the self-locking pin. 2 Remove the spacer. 3 Remove the BPP switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection Combination Switch: Testing and Inspection For further information regarding this component please refer to Turn Signal Switch; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Testing and Inspection > Page 10841 Combination Switch: Service and Repair For further information regarding this component please refer to Turn Signal Switch; Service and Repair. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 10845 Door Switch: Service and Repair REMOVAL 1. Remove the door trim panel. 2. Remove the door latch. For additional information, refer to Door Latch. 3. Remove the door opening warning lamp switch. 1 Lift the locking tab. 2 Rotate the door opening warning lamp switch counterclockwise. 3 Remove the door opening warning lamp switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Specifications Fog/Driving Lamp Switch: Specifications Fog Lamp Switch Mounting Bezel Screws 2-3 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Specifications > Page 10849 Exterior Lighting System Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Specifications > Page 10850 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Specifications > Page 10851 Fog/Driving Lamp Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. 3 Disconnect the electrical connectors. 3. Remove the fog lamp switch. 1 Remove the screws. 2 Remove the mounting bezel. 3 Release the two tabs and remove the fog lamp switch. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Specifications > Page 10852 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 10856 Hazard Warning Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 10857 Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 10858 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 10859 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams Headlamp Dimmer Switch: Diagrams For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 10863 Headlamp Dimmer Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 10864 Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 10865 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 10866 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Specifications Headlamp Switch: Specifications Head Lamp Switch Screws 2-3 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Specifications > Page 10870 Exterior Lighting System Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10873 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10874 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10875 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10876 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10877 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10878 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10879 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10880 Headlamp Switch: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10881 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10882 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10883 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10884 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10885 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10886 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 10887 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 10888 Headlamp Switch: Testing and Inspection Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 10889 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 10890 Headlamp Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the instrument panel steering column opening cover reinforcement; refer to Dashboard. 3. Remove the center instrument panel finish panel. 1 Remove the screws. 2 Remove the instrument panel finish panel. 4. Remove the instrument cluster finish panel. 1 Remove the screws. 2 Remove the cluster instrument panel finish panel. 5. Disconnect the headlamp switch electrical connectors and remove the headlamp switch knob. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 10891 6. Remove the headlamp switch. 1 Remove the screws. 2 Remove the headlamp switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation Horn Switch: Description and Operation The horn blow switches are underneath the driver side air bag module in the steering wheel. The switches are powered through the air bag sliding contact and ground through the steering column. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation > Page 10895 Horn Switch: Service and Repair REMOVAL 1. Remove the driver side air bag; refer to Air Bag Systems. 2. Remove the switches. 1 Disconnect the horn wire (BK) from the switches. 2 Remove the attaching bolts from the switches and remove the switches. INSTALLATION 1. To install, reverse the removal procedure. ^ Prove out the air bag system; refer to Air Bag Systems. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Service and Repair Interior Light Switch: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the interior lamp switch. 1 Disconnect the interior lamp switch electrical connector. 2 Remove the interior lamp switch. ^ Push inward; rotate counterclockwise. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Turn Signal Switch: Diagrams For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 10902 Turn Signal Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 10903 Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 10904 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 10905 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 10906 Turn Signal Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the upper and lower steering column shrouds. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 10907 5. Remove the multi-function switch. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 SOHC VIN K SFI (2001)) 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 10912 OASIS CODES: 201000, 201200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Specifications Tail Lamp: Specifications Rear lamp Assembly Screws 1.6-2.2 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Specifications > Page 10916 Exterior Lighting System Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions Tail 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10919 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10920 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10921 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10922 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10923 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10924 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10925 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10926 Tail Lamp: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10927 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10928 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10929 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10930 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10931 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10932 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10933 Tail Lamp: Electrical Diagrams For further information regarding this component please refer to : Lighting and Horns/Diagrams. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 10934 Tail Lamp: Testing and Inspection For Further information regarding the diagnosis of this component and the system that it is a part of, please refer to Lighting and Horns; Parking Lamp; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 10935 Tail Lamp: Service and Repair REMOVAL 1. Raise the liftgate and remove the rear lamp screws. 2. Remove the rear lamp. Disconnect the electrical connectors. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Trailer Lamps: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the trailer tow lights. 2. Verify the exterior lighting system of the vehicle is operating properly. If not, refer to the appropriate pinpoint test. 3. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Central Junction Box (CJB) Fuse 3 (7.5 A) ^ CJB Fuse 7 (7.5 A) ^ CJB Fuse 30 (15 A) ^ Loose or corroded connections ^ Damaged circuity ^ Damaged relays ^ Failed bulb(s) 4. If the fault is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10940 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10941 Trailer Lamps: Pinpoint Tests Connector Circuit Reference Refer to the Vehicle/Diagrams for schematic and connector information. AA1 - AA2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10942 AB1 - AB2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10943 AC1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10944 AD1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10945 AE1 - AE2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10946 73 Digital Multimeter Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Testing and Inspection Combination Switch: Testing and Inspection For further information regarding this component please refer to Turn Signal Switch; Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Testing and Inspection > Page 10951 Combination Switch: Service and Repair For further information regarding this component please refer to Turn Signal Switch; Service and Repair. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Turn Signal Lamp: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the turn signal/hazard flasher lamps. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART 3. If the fault is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10959 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10960 Turn Signal Lamp: Pinpoint Tests L1 - L2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10961 L3 - L4 Test M: Hazard Flasher Lamps Are Never ON Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10962 M1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10963 M2 - M3 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10964 M4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10965 N1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10966 Turn Signal Lamp: Component Tests and General Diagnostics Refer to Vehicle/Diagrams for schematic and connector information. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10967 Special Service Tool(s) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams Turn Signal Switch: Diagrams For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 10974 Turn Signal Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 10975 Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 10976 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 10977 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 10978 Turn Signal Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the upper and lower steering column shrouds. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 10979 5. Remove the multi-function switch. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Engine Compartment Lamp <--> [Underhood Lamp] > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 10985 OASIS CODES: 201000, 201200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Service and Repair Vanity Lamp: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the sun visor. ^ Position the sun visor as necessary. ^ Remove the sun visor screws. 3. Lower the sun visor and disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 10994 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 10995 Heated Glass Element Relay: Testing and Inspection Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 10996 Schematic Use 73III Automotive Meter to check for the continuity between terminal 85 and all other terminals. If resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 86 and 30 directly to the positive battery terminal. Use 73III Automotive Meter set in the volts position to check for voltage at terminal 87A. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 85, and ground the jumper wire to a known good ground. Check for voltage at terminal 87. If battery voltage is not indicated, replace the relay. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair Rear Defogger: Technical Service Bulletins A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair TSB 04-24-5 12/13/04 REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR TERMINAL TAB REPAIR FORD: 1999-2000 Contour 1999-2002 Escort 1999-2003 Escort ZX2 1999-2005 Crown Victoria, Mustang, Taurus 2000-2005 Focus 2005 Five Hundred, Freestyle 1999-2003 Windstar 1999-2005 Expedition, Explorer 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Escape 2004-2005 F-150, Freestar 2005 Escape Hybrid LINCOLN: 1999-2002 Continental 1999-2005 Town Car 2000-2005 LS 1999-2005 Navigator 2002-2003 Blackwood 2003-2005 Aviator MERCURY: 1999 Tracer 1999-2000 Mystique 1999-2005 and Marquis, Sable 2005 Montego 1999-2002 Villager 1999-2005 Mountaineer 2004-2005 Monterey 2005 Mariner This article supersedes TSB 04-18-9 to update vehicle applications and service procedure. ISSUE Some vehicles may exhibit inoperative electric rear window defroster (heated back lite) grid lines, integral antenna concerns causing radio reception issues or terminal tabs pulled from the rear window glass. ACTION Follow the diagnostic and repair procedures included in this article to inspect and service rear defroster grid lines, integral antenna concerns or broken terminal tabs. SERVICE PROCEDURE Warrantable/Non Warrantable repairs Warrantable grid line repairs typically can be identified by one inoperative grid line with a small discoloration at the area of concern, approximately the size of a pinhead. Grid line(s) that are scratched or have the silver material removed are not warrantable and should be addressed with the customer. Replacement of backglass for grid line or bus bar tarnishing is not a warrantable repair. Tarnishing of the silver lines or bus bars is a normal condition. Please refer to the Heated Back Lite Damageability Job Aid for additional information and examples of defects and damage. NOTE THE GRID LINE MATERIAL IS NOT EMBEDDED INTO THE GLASS BUT IS BAKED TO THE GLASS SURFACE AND CONSEQUENTLY CAN BE SCRAPED OFF. INOPERATIVE LINES MAY APPEAR TO THE EYE TO BE UNDAMAGED DUE TO RESIDUE REMAINING ON Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 11004 THE GLASS AND WILL REQUIRE DIAGNOSIS WITH A VOLTMETER OR 12V TEST LAMP AS EXPLAINED IN THIS ARTICLE. Examples Of Non-Warrantable Grid Line Damage ^ Ice scraper damage to grid lines ^ Animal scratches on grid lines ^ Window tint film/removal of the film which damages grid lines ^ Stickers placed over grids which upon removal, removes the grid line material ^ License plate (steel type placed against the inside of back glass) which rubs on the grid line causing damage ^ Temporary license plate (paper stuck on to the inside of the back glass) which upon removal removes grid line material ^ Cargo or lumber rubbing against the glass which removes grid line material ^ Cellular phone antenna installation/removal which damages grid line material NOTE AN UNDAMAGED GRIDLINE WILL HAVE SMALL RIDGES THAT PROJECT ABOVE THE SURFACE OF THE GLASS AND CAN EASILY BE FELT WHEN RUNNING A FINGERNAIL ACROSS THEM. GRIDLINES THAT HAVE BEEN "RAZOR BLADED" WILL FEEL SMOOTH WHEN A FINGERNAIL IS DRAGGED ACROSS THE AFFECTED AREA. THERE MAY BE SOME RESIDUE LEFT ON THE GLASS THAT APPEARS TO BE GRID MATERIAL BUT A CHECK WITH A VOLTMETER OR 12V TEST LAMP, AS EXPLAINED IN THIS ARTICLE, WILL CONFIRM AN OPEN CIRCUIT. GRID LINE INOPERATIVE - DIAGNOSTICS 1. Reference Workshop Manual Section 501-11 and the Wiring Diagram Section 56 to verify power and ground to the back-glass. 2. Connect a test lamp or DVOM to a good body ground. 3. Turn the ignition key to the run position and depress and release the rear defroster button to turn the system on. THE GRID IS ENERGIZED FOR APPROXIMATELY 10 MINUTES EACH TIME THE DEFROSTER BUTTON IS PRESSED. 4. Starting from the top grid line at the center of the back-glass, touch the test lamp or DVOM + lead to each grid line. (Use caution not to damage grid lines). The DVOM should read approximately 1/2 of the battery voltage on each line at the center of the back-glass. If using a test light, the bulb should be approximately the same brightness on each line from top to bottom. If the DVOM or light indicates a high voltage or no voltage on any grid line, move along the concern grid line with the + test lead or test lamp until the voltage changes suddenly. This is the area of concern, use chalk to mark the area of concern and mark the outside of the glass at that same area. 5. Repair per the Grid Line Repair Procedure. GRID LINE REPAIR PROCEDURE NOTE LONG GAPS ARE ALMOST ALWAYS DUE TO DAMAGE AND ARE NOT WARRANTABLE, HOWEVER THEY CAN BE REPAIRED. THE LONGER THE GAP THE MORE IMPORTANT IT IS TO APPLY A MINIMUM SIX (6) COATS OF CONDUCTIVE REPAIR MATERIAL WITH THE FIVE (5) MINUTE DRY TIME BETWEEN EACH COAT. APPLYING LESS COATS OR NOT ALLOWING DRY TIME BETWEEN COATS WILL PRODUCE REPAIRED RESISTANCE THAT IS GREATER THAN OEM RESISTANCE, RESULTING IN POOR DEFROST PERFORMANCE AND EXCESSIVE LOCALIZED HEATING. REPAIRED LONG GAPS ARE GENERALLY NOT VISUALLY PLEASING UNLESS EXTREME CARE IS TAKEN WHEN TAPING AFFECTED GRID LINE AREAS. NOTE IF THE BROWN COLOR UNDER THE GRID LINE IS DAMAGED OR MISSING (THIS IS VERY RARE), IT WILL BE NECESSARY TO APPLY BROWN ACRYLIC LACQUER TOUCH-UP PAINT FOR COLOR MATCH. THIS PAINT MUST MEET SPECIFICATION ESR-M2P100-C AND SHOULD BE APPLIED TO THE GLASS PRIOR TO APPLYING THE REAR WINDOW DEFROSTER REPAIR COMPOUND. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 11005 Service inoperative grid lines on rear window glass using Motorcraft Defroster Repair PM-11 or equivalent meeting Ford specification ESB-M4J58-A as follows: Surface Preparation 1. Bring vehicle inside and warm it to 60° F (16° C) or above. 2. Do not use scrapers, sharp instruments, or abrasive window cleaners on the interior surface of the rear window glass as this may cause damage to the grid lines. Clean the entire grid line service area with Ultra Clear Spray Glass Cleaner ZC-23 or equivalent meeting Ford specification ESR-M14P5-A to remove all dirt, wax, grease, oil or other foreign matter. It is important that the repair area be clean and dry. NOTE THE REPAIR AREA HOWEVER SHOULD BE CLEANED WITH STEEL WOOL OR AN ABRASIVE PAD SUCH AS SCOTCHBRITE TO REMOVE GRIME. Mixing The bottle of Rear Window Defroster Repair compound and touch-up paint (if needed) must be at room temperature. Shake the bottle for at least one (1) minute for thorough mixing. Shake frequently during use. Application 1. Mark location of open grid on the outside of the back window glass (performed in diagnostics). Place protective covering over the package tray as necessary. 2. Using "fine line tape", mask off the area directly above and below open grid line (Figure 1). It is best to extend the tape 26 mm (1") beyond the concern area in both directions. The open should be at the center of the mask and tape gap must be no wider than the existing grid line. Other types of tape may be used but end results of the repair may not appear as visually acceptable due to ease of application and tape edge finish. 3. If the brown layer of the grid is not broken or missing, apply only the silver grid repair compound to the open grid line. Apply the correct coating in several smooth continuous strokes (allowing five (5) minutes drying time between coats) across the open grid line area using the brush applicator in the cap. Extend the service coating at least 6 mm (.25") on both sides of the open grid line area. Apply a minimum of six (6) coats of the grid repair compound. 4. If both brown and silver layers of the grid are broken or missing, apply a coating of brown lacquer touch-up paint across the open line area first. Take care to paint only the area missing the color. Two (2) coats may be necessary to obtain the proper color. Allow the touch-up paint to dry at least five (5) minutes between coats. Apply six (6) coats of grid repair compound. NOTE THE INTERIOR SIDE OF THE GRID LINES ARE NOT PAINTED, BUT DUE TO THE SILVER TARNISHING WILL TEND TO CHANGE THE GRID TO A GOLD OR BROWN COLOR. THE REPAIRED AREA WILL BE BRIGHT SILVER AND WILL ALSO TARNISH OVER Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 11006 TIME TO MATCH THE REST OF THE GRID. 5. After five (5) minutes of dry time of the final coat of grid repair compound, remove the tape, step outside and inspect the repaired area. If the repair compound is visible above or below the grid, the excess can be removed. This may be done by placing a single-edge razor blade on the back window glass parallel to grid and scrape gently toward grid. A wider/thicker line will perform better but may not be cosmetically appealing. CAUTION BE CAREFUL NOT TO DAMAGE GRID LINE WITH RAZOR BLADE. VERIFY ALL OF THE GRID LINES FUNCTION PROPERLY WHEN FINISHED. Curing The service coating will air-dry in approximately one (1) minute and the system can be energized after five minutes. Maximum hardness and adhesion occur after approximately 24 hours. SOLDER METHOD OF LEAD TERMINAL NOTE THE REAR WINDOW MUST BE AT A MINIMUM OF 60° F (16° C) BEFORE A REPAIR IS MADE. PLACE PROTECTIVE COVERING OVER THE PACKAGE TRAY AS NECESSARY. The new terminal will cover the original terminal location, but must be placed so that the new terminal conductive areas will be placed on a good conductive base. This area should be cleaned with steel wool or an abrasive pad to remove grime from the buss-bar. The area should then be cleaned with Ultra Clear Spray Glass Cleaner, ZC-23, or equivalent meeting Ford specification ESR-M14P5-A to remove all dirt, wax, grease, oil or other foreign matter. It is important that the repair area be clean and dry and appear metallic. Depending on the buss-bar condition, rigorous polishing with steel wool may be required. Please note that the entire buss-bar may be cleaned to improve appearance. CAUTION DO NOT USE ANY TYPE OF FLAME TORCH OR FLAME HEATED SOLDERING GUN FOR THIS PROCEDURE. TESTING INDICATED INADEQUATE HEAT GENERATION AT THE TIP AND THE EXHAUST HEAT CAN CAUSE DAMAGE TO PLASTIC TRIM PARTS IN THE AREA. USE ONLY AN ELECTRIC SOLDERING GUN WITH 100 WATTS OR MORE OF POWER. BEFORE USING THE SOLDERING GUN, BE SURE TO MELT A SMALL AMOUNT OF ROSIN CORE SOLDER TO THE TIP. THE SOLDER WILL ASSIST IN ACHIEVING BETTER HEAT TRANSFER FROM THE SOLDERING GUN TIP TO THE NEW TERMINAL. The new terminal has pre-applied solder, flux and temperature sensitive paint. The paint provides a visual indication when the terminal has reached the proper temperature to melt the solder on the terminal. When the proper temperature is achieved the temperature paint will liquefy and change color. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 11007 Use terminal type A (Figure 2) for all tab locations except on the Focus vehicle line. For the Focus, use type B (Figure 3). NOTE DEPENDING ON THE ORIGINAL TERMINAL LOCATION, AND WHETHER THE TERMINAL IS COVERED BY PILLAR TRIM, WILL DETERMINE WHERE TO LOCATE THE NEW TERMINAL. SOME GRID LINE BUSS-BARS MAY ONLY ALLOW THE PLACEMENT OF THE TERMINAL ABOVE OR BELOW THE ORIGINAL TAB LOCATION DUE TO SPACE LIMITATIONS, BUT FOR MOST VEHICLE APPLICATIONS THE REPLACEMENT TAB LOCATION WILL COVER THE ORIGINAL TAB LOCATION BUT STILL ALLOW THE REPLACEMENT TAB TO ATTACH TO THE BUSS-BAR ON GOOD CONDUCTIVE MATERIAL. 1. Place the replacement terminal over the original tab location making sure the conductive areas of the terminal will be on a good conductive area. Do not place the terminal tab foot on the original location which does not have conductive material (figure 4). 2. Hold the terminal in place with an item such as regular lead pencil at a 90 degree angle from the terminal. (Terminal type B can be held in place with tape.) (Holding at other than a 90 degree angle may allow the terminal to slip when the solder liquefies). 3. Place the soldering gun tip on the top of the terminal but not on the painted areas of the tab. Energize the soldering gun and watch for the painted area of the terminal to liquefy and change color. The paint should liquefy in approximately 25-45 seconds after heating. As soon as the paint color completely changes on either side of the terminal, de-energize the soldering gun and continue to hold the terminal in place with the soldering gun and pencil for an additional thirty (30) seconds. 4. Remove the soldering gun and pencil from the terminal. The terminal should be allowed to cool for another two (2) minutes before the wiring lead is attached to the terminal. 5. Attach the electrical lead connection to this terminal, turn on the rear defroster, and verify operation. Parts Block Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 11008 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042405A Repair Grid Lines (Includes 0.7 Hr. Time To Diagnose And Recheck) 042405B Replace Terminal (Includes 0.4 Hr. Time To Diagnose And Recheck) 042405C Repair Grid Lines And 0.8 Hr. Replace Terminal (Includes Time To Diagnose And Recheck) DEALER CODING CONDITION BASIC PART NO. CODE 7042006 28 Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 11013 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 11014 Heated Glass Element Relay: Testing and Inspection Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 11015 Schematic Use 73III Automotive Meter to check for the continuity between terminal 85 and all other terminals. If resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 86 and 30 directly to the positive battery terminal. Use 73III Automotive Meter set in the volts position to check for voltage at terminal 87A. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 85, and ground the jumper wire to a known good ground. Check for voltage at terminal 87. If battery voltage is not indicated, replace the relay. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions Power Window Control Module: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11021 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11022 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11023 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11024 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11025 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11026 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11027 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11028 Power Window Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11029 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11030 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11031 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11032 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11033 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11034 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Page 11035 Power Window Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Page 11036 Power Window Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Page 11037 Power Window Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 11041 Power Window Relay: Description and Operation LH Front Window Regulator Control Switch Inputs Table The GEM controls manual down and OTD window movement with the OTD relay. The relay is activated by applying ground directly to one side of the down window relay coil, and is deactivated by removing the ground signal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 11042 Power Window Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Specifications Power Window Switch: Specifications Rear Window Regulator Switch Plate Screws 1.4-2.0 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch Power Window Switch: Diagrams Power Window Switch 2 Door Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 11052 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 11053 4 Door Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 11054 Power Window Switch: Description and Operation The window regulator control switch: ^ Is located on each door trim panel. ^ May be used to raise or lower both LH side and RH side windows from the master control on the driver door. ^ Includes a window lock feature that is controlled through the master control. ^ Can manually lower the driver side window when the master control is depressed longer than 0.4 seconds. ^ The driver side window can be completely lowered when the master control is depressed between 0.04 and 0.4 seconds and then released. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch Power Window Switch: Testing and Inspection Master Window Control Switch Component Testing Procedure Component Testing Procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 11057 Terminals Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 11058 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 11059 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 11060 Power Window Switch: Testing and Inspection Power window Switch Right Front Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 11061 Schematic Left Rear Component Testing Procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 11062 Terminals Schematic Right Rear Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 11063 Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 11064 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Driver Door Power Window Switch: Service and Repair Driver Door REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front door trim panel. 3. Remove the window regulator switch plate harness assembly. 1 Remove the screws. 2 Remove the harness assembly. 4. Remove the window regulator control switch. 1 Pry the release tabs. 2 Remove the window regulator control switch. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Driver Door > Page 11067 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Driver Door > Page 11068 Power Window Switch: Service and Repair Rear Door REMOVAL 1. Remove the rear window regulator switch plate. 1 Remove the screws. 2 Remove the rear window regulator switch plate. 2. Remove the window regulator switch plate harness assembly. 1 Remove the screws. 2 Remove the harness assembly. 3. Remove the window regulator control switch. 1 Pry the release tabs. 2 Remove the window regulator control switch. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Driver Door > Page 11069 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions Power Window Control Module: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11076 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11077 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11078 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11079 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11080 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11081 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11082 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11083 Power Window Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11084 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11085 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11086 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11087 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11088 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11089 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Page 11090 Power Window Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Page 11091 Power Window Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Page 11092 Power Window Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Specifications Front Door Window Motor: Specifications Power Window Motor Nuts 5.6-9.1 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Specifications > Page 11097 Front Door Window Motor: Service Precautions WARNING: PRIOR TO POWER WINDOW REMOVAL, ENSURE THE REGULATOR ARMS ARE IN A FIXED POSITION TO PREVENT COUNTERBALANCE SPRING UNWIND. FAILURE TO PLACE THE REGULATOR ARMS IN A FIXED POSITION CAN CAUSE THE SPRING TO SUDDENLY RELEASE RESULTING IN PERSONAL INJURY. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Specifications > Page 11098 Front Door Window Motor: Service and Repair Heavy Duty Riverter SPECIAL SERVICE TOOLS REMOVAL 1. Raise the front door window glass to the full up position. 2. Remove the front door trim panel. 3. Disconnect the battery ground cable. 4. Disconnect the inside front door handle from the front door. 1 Remove the screws. 2 Disconnect the inside front door handle. 5. Disconnect the rod from the inside front door handle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Specifications > Page 11099 6. Support the front door window glass. 7. If equipped, disconnect the power window motor electrical connector. 8. If equipped, remove the equalizer bracket to front door inner panel nuts. 9. Remove the window regulator/motor assembly. 1 Drill out the rivets. 2 Remove the nut. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Specifications > Page 11100 10. If equipped, remove the power window motor. 1 Remove the bolts. 2 Remove the power window motor. WARNING: PRIOR TO POWER WINDOW REMOVAL, ENSURE THE REGULATOR ARMS ARE IN A FIXED POSITION TO PREVENT COUNTERBALANCE SPRING UNWIND. FAILURE TO PLACE THE REGULATOR ARMS IN A FIXED POSITION CAN CAUSE THE SPRING TO SUDDENLY RELEASE RESULTING IN PERSONAL INJURY. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Specifications > Page 11101 1. To install, reverse the removal procedure. ^ Use Heavy Duty Riveter to install the new rivets. ^ Cycle the door glass to ensure engagement of the drive mechanism. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Specifications > Page 11102 Heavy Duty Riveter Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Specifications Rear Door Window Motor: Specifications Power Window Motor Nuts 5.6-9.1 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Specifications > Page 11106 Rear Door Window Motor: Service Precautions WARNING: PRIOR TO POWER WINDOW REMOVAL, ENSURE THE REGULATOR ARMS ARE IN A FIXED POSITION TO PREVENT COUNTERBALANCE SPRING UNWIND. FAILURE TO PLACE THE REGULATOR ARMS IN A FIXED POSITION CAN CAUSE THE SPRING TO SUDDENLY RELEASE RESULTING IN PERSONAL INJURY. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Specifications > Page 11107 Rear Door Window Motor: Service and Repair REMOVAL 1. Raise and support the rear door window glass to the full up position. 2. Disconnect the battery ground cable. 3. Remove the rear door trim panel. 4. Remove the speaker. 1 Remove the screws. 2 Disconnect the electrical connector. 3 Remove the speaker. 5. Remove the watershield. 6. Remove the power window motor. 1 Remove the bolts. 2 Disconnect the electrical connector. 3 Remove the power window motor. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Specifications > Page 11108 1. To install, reverse the removal procedure. ^ Cycle the door glass to ensure engagement of the drive mechanism. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Specifications > Page 11109 Heavy Duty Riveter Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Page 11113 Power Window Relay: Description and Operation LH Front Window Regulator Control Switch Inputs Table The GEM controls manual down and OTD window movement with the OTD relay. The relay is activated by applying ground directly to one side of the down window relay coil, and is deactivated by removing the ground signal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Page 11114 Power Window Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Specifications Power Window Switch: Specifications Rear Window Regulator Switch Plate Screws 1.4-2.0 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Power Window Switch Power Window Switch: Diagrams Power Window Switch 2 Door Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 11120 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 11121 4 Door Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Page 11122 Power Window Switch: Description and Operation The window regulator control switch: ^ Is located on each door trim panel. ^ May be used to raise or lower both LH side and RH side windows from the master control on the driver door. ^ Includes a window lock feature that is controlled through the master control. ^ Can manually lower the driver side window when the master control is depressed longer than 0.4 seconds. ^ The driver side window can be completely lowered when the master control is depressed between 0.04 and 0.4 seconds and then released. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch Power Window Switch: Testing and Inspection Master Window Control Switch Component Testing Procedure Component Testing Procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 11125 Terminals Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 11126 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 11127 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 11128 Power Window Switch: Testing and Inspection Power window Switch Right Front Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 11129 Schematic Left Rear Component Testing Procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 11130 Terminals Schematic Right Rear Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 11131 Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Control Switch > Page 11132 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Driver Door Power Window Switch: Service and Repair Driver Door REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front door trim panel. 3. Remove the window regulator switch plate harness assembly. 1 Remove the screws. 2 Remove the harness assembly. 4. Remove the window regulator control switch. 1 Pry the release tabs. 2 Remove the window regulator control switch. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Driver Door > Page 11135 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Driver Door > Page 11136 Power Window Switch: Service and Repair Rear Door REMOVAL 1. Remove the rear window regulator switch plate. 1 Remove the screws. 2 Remove the rear window regulator switch plate. 2. Remove the window regulator switch plate harness assembly. 1 Remove the screws. 2 Remove the harness assembly. 3. Remove the window regulator control switch. 1 Pry the release tabs. 2 Remove the window regulator control switch. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Driver Door > Page 11137 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair Heavy Duty Riverter SPECIAL SERVICE TOOL(S) REMOVAL 1. Remove the front door trim panel. 2. Remove the inside glass weatherstrip. 3. Drill out the window regulator arm to window glass rivets. NOTE: Lower the window glass to access the two rivets. 4. Remove the front door window glass. NOTE: Slide the glass through the outboard side of the front door. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair > Page 11142 INSTALLATION 1. Position the front door window glass. NOTE: Slide the glass through the outboard side of the front door. 2. Use Heavy Duty Riveter to install the window regulator arm to window glass rivets. 3. Install the inside glass weatherstrip. 4. Install the front door trim panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair REMOVAL 1. Open the liftgate glass. 2. Disconnect the two rear window defogger electrical connectors (one on each side). 3. Disconnect the two liftgate cylinders (one on each side). 4. Release the upper liftgate trim panel clips to gain access to liftgate window glass access plugs. 5. Remove the liftgate glass hinge access plugs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Page 11146 6. Remove the liftgate window glass. 1 Remove the two liftgate window glass to window hinge nuts. 2 Remove the liftgate window glass. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Movable Quarter Quarter Window Glass: Service and Repair Movable Quarter REMOVAL 1. Remove the quarter trim panel. 2. Remove the quarter window glass. 1 Remove the nuts. 2 Remove the quarter window glass. INSTALLATION 1. To install, reverse the removal procedure. NOTE: If the seal requires adjustment, disconnect the quarter trim panel. Rotate the quarter window latch clockwise to increase seal pressure or counterclockwise to reduce seal pressure. Reconnect the quarter window latch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Movable Quarter > Page 11151 Quarter Window Glass: Service and Repair Quarter REMOVAL 1. Remove the quarter trim panel. 2. Remove the rear quarter window glass. 1 Remove the ten nuts. 2 Carefully push the rear quarter window glass outward to release the butyl seal. 3. Remove the excess foam butyl from the window opening. INSTALLATION 1. Apply 6 mm (0.23 in) foam butyl or equivalent meeting Ford specification WSB-M2G234-C to the rear quarter window glass frame. ^ Start at the bottom middle and work around the frame. NOTE: When applying foam butyl, leave a slight overlap at the bottom to allow for drainage. 2. Install the rear quarter window glass. 1 Position the rear quarter window glass. 2 Tighten the ten nuts to specification. NOTE: Loosely install the ten nuts before tightening. 3. Install the quarter trim panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair Heavy Duty Riverter SPECIAL SERVICE TOOL(S) REMOVAL 1. Remove the rear door trim panel. 2. Remove the inside glass weatherstrip. 3. Drill out the window regulator arm to window glass rivets. 4. Remove the rear door window glass. NOTE: Slide the glass through the outboard side of the rear door. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair > Page 11155 1. Position the rear door window glass. NOTE: Slide the glass through the outboard side of the rear door. 2. Use Heavy Duty Riveter to install the window regulator arm to window glass rivets. 3. Install the inside glass weatherstrip. 4. Install the rear door trim panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Specifications Front Door Window Regulator: Specifications Rear Window Glass Regulator Nut 10-14 Nm Window Regulator Switch Plate Harness Assembly 2-3 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Specifications > Page 11160 Front Door Window Regulator: Service Precautions WARNING: PRIOR TO POWER WINDOW REMOVAL, ENSURE THE REGULATOR ARMS ARE IN A FIXED POSITION TO PREVENT COUNTERBALANCE SPRING UNWIND. FAILURE TO PLACE THE REGULATOR ARMS IN A FIXED POSITION CAN CAUSE THE SPRING TO SUDDENLY RELEASE RESULTING IN PERSONAL INJURY. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Specifications > Page 11161 Front Door Window Regulator: Service and Repair Heavy Duty Riverter SPECIAL SERVICE TOOLS Motor and Window Regulator - Front Door REMOVAL 1. Raise the front door window glass to the full up position. 2. Remove the front door trim panel. 3. Disconnect the battery ground cable. 4. Disconnect the inside front door handle from the front door. 1 Remove the screws. 2 Disconnect the inside front door handle. 5. Disconnect the rod from the inside front door handle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Specifications > Page 11162 6. Support the front door window glass. 7. If equipped, disconnect the power window motor electrical connector. 8. If equipped, remove the equalizer bracket to front door inner panel nuts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Specifications > Page 11163 9. Remove the window regulator/motor assembly. 1 Drill out the rivets. 2 Remove the nut. 10. If equipped, remove the power window motor. 1 Remove the bolts. 2 Remove the power window motor. WARNING: PRIOR TO POWER WINDOW REMOVAL, ENSURE THE REGULATOR ARMS ARE IN A FIXED POSITION TO PREVENT COUNTERBALANCE SPRING UNWIND. FAILURE TO PLACE THE REGULATOR ARMS IN A FIXED POSITION CAN CAUSE THE SPRING TO SUDDENLY RELEASE RESULTING IN PERSONAL INJURY. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Specifications > Page 11164 1. To install, reverse the removal procedure. ^ Use Heavy Duty Riveter to install the new rivets. ^ Cycle the door glass to ensure engagement of the drive mechanism. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Specifications > Page 11165 Heavy Duty Riveter Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Specifications Rear Door Window Regulator: Specifications Rear Window Glass Regulator Nut 10-14 Nm Window Regulator Switch Plate Harness Assembly 2-3 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Specifications > Page 11169 Rear Door Window Regulator: Service and Repair Heavy Duty Riverter SPECIAL SERVICE TOOLS REMOVAL 1. Remove the rear door trim panel. 2. Disconnect the inside rear door handle from the rear door. 1 Remove the screws. 2 Disconnect the inside rear door handle. 3. Disconnect the rod from the inside rear door handle. 4. Remove the speaker. 1 Remove the screws. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Specifications > Page 11170 2 Disconnect the electrical connector. 3 Remove the speaker. 5. Remove the watershield. 6. Raise and support the rear door window glass to the full up position. 7. Disconnect the battery ground cable. 8. If equipped, disconnect the power window electrical connector. 9. Drill out the window regulator rivets. 10. Remove the rear door window regulator. ^ Slide the regulator arms off of the window glass track. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Specifications > Page 11171 1. To install, reverse the removal procedure. ^ Use Heavy Duty Riveter to install the new rivets. ^ Cycle the door glass to ensure engagement of the drive mechanism. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Specifications > Page 11172 Heavy Duty Riveter Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Technician Safety Information Windshield: Technician Safety Information WARNING: TO PREVENT GLASS SPLINTERS FROM ENTERING THE EYES OR CUTTING HANDS, WEAR SAFETY GLASSES AND HEAVY GLOVES WHEN CUTTING THE GLASS FROM THE VEHICLE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Technician Safety Information > Page 11177 Windshield: Vehicle Damage Warnings CAUTION: ^ If the vehicle is to be driven within 24 hours of urethane application, urethane sealant Essex U-216 must be used due to its one hour cure time. ^ After installing the urethane installed glass, the vehicle should not be driven until the urethane has cured. The curing times at temperatures above 13°C (55°F) and relative humidity above 50% is 12 - 24 hours (decreasing at higher temperatures and lower humidities). Inadequate curing of the urethane may adversely affect the strength of the urethane bond. ^ Do not scratch the pinch weld area. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 11178 Windshield: Description and Operation Windshield Glass The windshield glass: ^ Is standard plastic and glass laminate safety glass. ^ Is bonded to the window opening flange with urethane sealant. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 11179 Windshield: Service and Repair SPECIAL SERVICE TOOLS REMOVAL WARNING: TO PREVENT GLASS SPLINTERS FROM ENTERING THE EYES OR CUTTING HANDS, WEAR SAFETY GLASSES AND HEAVY GLOVES WHEN CUTTING THE GLASS FROM THE VEHICLE. 1. Remove the windshield side garnish moldings. 2. Remove the interior rear view mirror. For additional information, refer to Mirrors. 3. If equipped, remove the overhead console. Refer to Interior Trim. 4. Remove the sun visors. 1 Remove the sun visor screws. 2 Remove the sun visors. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 11180 ^ If equipped, disconnect the electrical connector. 5. Remove the sun visor clips. 1 Remove the sun visor clip screws. 2 Remove the sun visor clips. 6. Lower the front portion of the headliner. 7. Remove the cowl grille. 8. Remove the upper windshield weatherstrip. 9. Remove the LH and RH windshield mouldings. 10. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld. 11. Using the special tool, cut the urethane sealant from the windshield glass starting at the top center and work toward the bottom corners. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 11181 NOTE: Lubricate the urethane sealant with water to aid the special tool when cutting. 12. Using the special tool, distance the windshield from the body. 13. Using the special tool, cut the remaining urethane sealant and remove the windshield glass. 14. Using a soft brush or vacuum, remove any foreign material or dirt from the pinch weld. INSTALLATION CAUTION: After installing the urethane installed glass, the vehicle should not be driven until the urethane has cured. The curing times at temperatures above 13°C (55°F) and relative humidity above 50% is 12 - 24 hours (decreasing at higher temperatures and lower humidities). Inadequate curing of the urethane may adversely affect the strength of the urethane bond. 1. Dry fit the windshield. Make alignment marks with tape or non-staining grease pencil. 2. Trim the remaining urethane sealant on the pinch weld to within the specification. ^ The existing urethane sealant surface should be smooth and free of cuts and contamination. CAUTION: Do not scratch the pinch weld area. 3. Use a wool applicator to apply Urethane Metal Primer Essex U-413 meeting Ford specification WSB-M2G234-C to any exposed metal on the pinch weld. Allow six to ten minutes to dry. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 11182 4. Apply (A) Foam Butyl meeting Ford specification WSB-M2G234-C to the (B) pinch weld. 5. If reinstalling original windshield, remove the excess urethane sealant from the windshield glass. 6. Clean the inside of the glass surface with an alcohol-free cleaner making sure the ceramic coated area is clean. 7. Apply Urethane Glass Prep Essex U-401 meeting Ford specification WSB-M2G314-B twice around the glass surface to be urethaned. NOTE: Wipe off the Glass Prep immediately after each application because it flash dries. 8. Apply Glass Primer Essex U-402 meeting Ford specification WSB-M5B280-C to the same area that was prepped in the pervious step. Allow five minutes to dry. 9. Cut the urethane applicator tip to specification. 10. Apply a bead of urethane sealant Essex 400-HV or Essex U-216, which meets Ford specification WSB-M2G316-B to the pinch weld just outside the foam dam. CAUTION: If the vehicle is to be driven within 24 hours of urethane application, urethane sealant Essex U-216 must be used due to its one hour cure time. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 11183 11. Install the windshield glass aligning it to the marks previously made. 12. After the windshield glass is set , check for water leaks and add urethane sealant where needed. 13. Install the upper windshield weatherstrip. 14. If necessary, remove excess urethane from the outside surface of the windshield glass. 15. Install the LH and RH windshield mouldings. 16. Install the cowl grille. 17. If equipped, install the overhead console. 18. Install the sun visor clips. 1 Install the sun visor clips. 2 Install the screws. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 11184 19. Install the sun visors. 1 Install the sun visors. ^ If equipped, connect the electrical connector. 2 Install the screws. 20. Install the front portion of the headliner. 21. Install the interior rear view mirror. For additional information, refer to Mirrors. 22. Install the windshield side garnish mouldings. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 11185 Windshield: Tools and Equipment SPECIAL SERVICE TOOLS Foam Butyl .......................................................................................................................................... ........................................................ WSB-M2G234-C Urethane Glass Prep Essex U-401 .............................................................................................................................................................. WSB-M2G314-B Urethane Glass Primer Essex U-402 ........................................................................................................................................................... WSB-M5B280-C Urethane Metal Primer Essex U-413 .......................................................................................................................................................... WSB-M2G234-C Urethane Sealant Essex U-216 ............................................................................... ..................................................................................... WSB-M2G316-B Urethane Sealant Essex 400-HV ................................................................................................................................................ ................. WSB-M2G316-B Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Locations Rear Wiper And Washer System Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Control Module: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11196 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11197 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11198 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11199 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11201 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11202 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11203 Windshield Washer Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11204 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11205 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11206 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11207 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11208 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11209 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Page 11210 Windshield Washer Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Page 11211 Windshield Washer Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Page 11212 Windshield Washer Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay > Page 11217 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 11218 Windshield Washer Relay: Testing and Inspection Testing an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper wires and 73 Digital Multimeter. Remove the relay to be tested from the power distribution box, fuse junction panel or individual connector. Terminals Component Testing Procedure Schematic Micro ISO Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 11219 Use the multimeter to check for the continuity between terminal 2 and all other terminals. If the resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 1 and 3 directly to the positive battery terminal. Use the multimeter set in the volts position to check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 2 and ground the jumper wire to a known good ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions Wiper Control Module: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11225 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11226 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11227 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11228 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11229 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11230 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11231 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11232 Wiper Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11233 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11234 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11235 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11236 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11237 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11238 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Page 11239 Wiper Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Page 11240 Wiper Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Page 11241 Wiper Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up Relay Wiper Relay: Locations Rear Wiper Up Relay Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up Relay > Page 11246 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up Relay > Page 11247 Wiper Relay: Locations Rear Wiper Down Relay Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up Relay > Page 11248 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up Relay > Page 11249 Wiper Relay: Locations Wiper High Relay Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up Relay > Page 11250 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up Relay > Page 11251 Wiper Relay: Locations Wiper Low Relay Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up Relay > Page 11252 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up Relay > Page 11253 Wiper Relay: Locations Wiper Park Relay Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up Relay > Page 11254 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 11255 Wiper Relay: Testing and Inspection Testing an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper wires and 73 Digital Multimeter. Remove the relay to be tested from the power distribution box, fuse junction panel or individual connector. Terminals Component Testing Procedure Schematic Micro ISO Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 11256 Use the multimeter to check for the continuity between terminal 2 and all other terminals. If the resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 1 and 3 directly to the positive battery terminal. Use the multimeter set in the volts position to check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 2 and ground the jumper wire to a known good ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications Windshield Washer Switch: Specifications Windshield Wiper Washer Switch 2-3 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 11261 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Multifunction Switch Windshield Washer Switch: Diagrams Multifunction Switch For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Multifunction Switch > Page 11264 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 11265 Windshield Washer Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 11266 Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 11267 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 11268 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 11269 Windshield Washer Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the upper and lower steering column shrouds. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 11270 5. Remove the multi-function switch. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Rear Wiper And Washer System Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 11274 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Multifunction Switch Wiper Switch: Diagrams Multifunction Switch For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Multifunction Switch > Page 11277 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 11278 Wiper Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 11279 Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 11280 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 11281 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Rear Wiper Switch Wiper Switch: Service and Repair Rear Wiper Switch REMOVAL 1. Remove the instrument panel finish panel. 1 Remove the two screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 2. Remove the rear wiper/washer switch. 1 Remove the screws. 2 Remove the mounting bezel. 3 Release the two tabs and remove the rear wiper/washer switch. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Rear Wiper Switch > Page 11284 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Rear Wiper Switch > Page 11285 Wiper Switch: Service and Repair Multifunction Switch Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Rear Wiper Switch > Page 11286 2 Remove the upper and lower steering column shrouds. 5. Remove the multi-function switch. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Description and Operation Washer Fluid Level Indicator: Description and Operation This warning message is displayed when there is less than one quarter of the container of washer fluid remaining ^ When the washer fluid level is normal, the windshield washer reservoir fluid level sensor will close, grounding the input Circuit 82 (PK/YE) at C200931 of the message center indicator. ^ When the washer fluid level is low, the input to the message center indicator will be open and the warning will be displayed. The message center indicator filters this input therefore, there will be a 20-second delay before the warning is displayed or removed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Control Module: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11295 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11296 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11297 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11298 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11299 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11300 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11301 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11302 Windshield Washer Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11303 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11304 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11305 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11306 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11307 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11308 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Page 11309 Windshield Washer Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Page 11310 Windshield Washer Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Page 11311 Windshield Washer Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Locations Rear Washer Hose Location And Routing Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Locations > Page 11315 Windshield Washer Hose: Description and Operation Wipers and Washers-Rear Washer Hose Fluid for the rear washer is supplied by a two-way washer pump located in the windshield washer fluid reservoir in the engine compartment. The rear washer hose contains a check valve, which is located in the hose that passes through the liftgate in the rear of the vehicle. This check valve holds the entire line full of washer fluid between washer operation. There is also a stand pipe located along the right hand D-pillar of the vehicle. This stand pipe prevents the unintentional release of washer fluid from the rear washer nozzle. If the hose is cut or disconnected after the line was initially primed with fluid, and the washer system is turned on, the stand pipe may fill with fluid. To resolve this, once the hose is repaired, temporarily disconnect the check valve to allow fluid in stand pipe to drain to lowest point in the hose; then reinstall the check valve. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Locations > Page 11316 Windshield Washer Hose: Service and Repair 1. Locate and verify the leaking washer hose. 2. Cut the hose cleanly and remove the damaged portion of the washer hose. 3. Install a windshield washer hose adapter between the cut ends of the hose. 4. Install a segment of 6.4 mm (0.25 in) i.d. black rubber hose N809610-S or equivalent over the ends of the washer hose, and clamp both ends of the rubber hose using spring clamps 389252-S101 or equivalent. NOTE: In difficult cases, clamping may be required. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations Wiper And Washer Systems Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 11320 Windshield Washer Pump: Service and Repair REMOVAL 1. Disconnect the windshield washer hose from the windshield washer pump. NOTE: To prevent spilling windshield washer fluid, drain the windshield washer reservoir before removal. 2. Disconnect the coolant overflow hose from the engine coolant overflow reservoir and plug the outlet of the reservoir. 3. Disconnect the windshield washer reservoir pump electrical connector and low level washer fluid electronic sensor connector, if equipped. 4. Remove the engine air cleaner; refer to Fuel Delivery and Air Induction. 5. Remove the two screws and two nuts and remove the windshield washer reservoir. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 11321 6. Remove the windshield washer pump. NOTE: Make sure not to tear the rubber grommet during disassembly. INSTALLATION 1. To install, reverse the removal procedure. NOTE: The windshield washer reservoir, windshield washer pump and the windshield washer reservoir fluid level sensor are replaced separately. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Front Washer Pump Relay > Page 11326 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 11327 Windshield Washer Relay: Testing and Inspection Testing an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper wires and 73 Digital Multimeter. Remove the relay to be tested from the power distribution box, fuse junction panel or individual connector. Terminals Component Testing Procedure Schematic Micro ISO Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 11328 Use the multimeter to check for the continuity between terminal 2 and all other terminals. If the resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 1 and 3 directly to the positive battery terminal. Use the multimeter set in the volts position to check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 2 and ground the jumper wire to a known good ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Specifications Windshield Washer Reservoir: Specifications Windshield Wiper/Washer Reservoir Screw and Nut 5-6 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Specifications > Page 11332 Wiper And Washer Systems Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Specifications > Page 11333 Windshield Washer Reservoir: Service and Repair REMOVAL 1. Disconnect the windshield washer hose from the windshield washer pump. NOTE: To prevent spilling windshield washer fluid, drain the windshield washer reservoir before removal. 2. Disconnect the coolant overflow hose from the engine coolant overflow reservoir and plug the outlet of the reservoir. 3. Disconnect the windshield washer reservoir pump electrical connector and low level washer fluid electronic sensor connector, if equipped. 4. Remove the engine air cleaner; refer to Fuel Delivery and Air Induction. 5. Remove the two screws and two nuts and remove the windshield washer reservoir. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Specifications > Page 11334 6. Remove the windshield washer pump. NOTE: Make sure not to tear the rubber grommet during disassembly. INSTALLATION 1. To install, reverse the removal procedure. NOTE: The windshield washer reservoir, windshield washer pump and the windshield washer reservoir fluid level sensor are replaced separately. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Locations Windshield Washer Spray Nozzle: Locations Rear Wiper And Washer System Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Locations > Page 11338 Wiper And Washer Systems Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications Windshield Washer Switch: Specifications Windshield Wiper Washer Switch 2-3 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Specifications > Page 11342 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Multifunction Switch Windshield Washer Switch: Diagrams Multifunction Switch For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Multifunction Switch > Page 11345 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 11346 Windshield Washer Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 11347 Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 11348 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 11349 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 11350 Windshield Washer Switch: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the upper and lower steering column shrouds. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 11351 5. Remove the multi-function switch. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the multi-function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications Wiper Arm: Specifications PivotArm-RearNut 13-17 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Page 11355 Wiper Arm: Locations Rear Wiper And Washer System Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Page 11356 Wiper And Washer Systems Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Page 11357 Wiper Arm: Service Precautions CAUTION: Use a shop towel or similar device to protect the vehicle finish when performing the procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Pivot Arm-Front Wiper Arm: Service and Repair Pivot Arm-Front REMOVAL 1. Remove the pivot arm. 1 Pull upon the pivot arm. 2 Pull out on the retainer tab and remove the pivot arm. NOTE: The windshield wiper pivot arms are replaced as an assembly. INSTALLATION 1. To install. reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Pivot Arm-Front > Page 11360 Wiper Arm: Service and Repair Pivot Arm-Rear REMOVAL CAUTION: Use a shop towel or similar device to protect the vehicle finish when performing the procedure. 1. Disconnect the rear washer hose. 2. Remove rear pivot arm. 1 Lift the pivot arm nut cover. 2 Remove the nut. 3 Remove the pivot arm. INSTALLATION 1. Turn the rear wiper switch on and allow the motor to operate for at least one cycle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Pivot Arm-Front > Page 11361 2. Turn the rear wiper switch OFF. NOTE: This step ensures that the wiper motor is in the park position. 3. Position the wiper blade outside the wiper arm stop. 4. Install the wiper pivot arm onto the wiper motor. ^ Tighten retaining nut. 5. Connect the washer hose. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Pivot Arm-Front > Page 11362 6. Cycle the wiper motor one time to allow the wiper arm to park on the wiper arm stop. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Locations Wiper Blade: Locations Wiper And Washer Systems Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Locations > Page 11366 Rear Wiper And Washer System Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions Wiper Control Module: 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 SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11372 Diagram 13-7 (Sample Power Distribution Diagram Page) 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 indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11373 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11374 Diagram 10-1 (Sample Grounds Diagram Page) 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 indicating which diagram page the circuit went to/came from. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11375 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11376 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11377 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11378 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11379 Wiper Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11380 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11381 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11382 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11383 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11384 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11385 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Page 11386 Wiper Control Module: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Page 11387 Wiper Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Page 11388 Wiper Control Module: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications Wiper Motor: Specifications Rear Wiper Motor Bolts 9-12 Nm Windshield Wiper Motor Bolts 7.0-9.0 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page 11392 Wiper Motor: Locations Wiper And Washer Systems Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page 11393 Rear Wiper And Washer System Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page 11394 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page 11395 Wiper Motor: Service Precautions CAUTION: ^ Do not handle the wiper motor abusively when diagnosing the wiper operations. Failure to follow this caution may result in damage to the motor magnets and will make the wiper motor inoperative. Rough handling of new replacement wiper motors may also damage the motor magnets. ^ The internal permanent magnets used in the windshield wiper motor are made of a glass-like material. To avoid damaging the magnets, do not strike the motor with a hammer or any other object. ^ To avoid possible damage to the mounting arm and pivot shaft retainer clip, be sure the clip is fully seated before installing on the motor crank pin. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page 11396 Wiper Motor: Testing and Inspection CAUTION: Do not handle the wiper motor abusively when diagnosing the wiper operations. Failure to follow this caution may result in damage to the motor magnets and will make the wiper motor inoperative. Rough handling of new replacement wiper motors may also damage the motor magnets. Use Alternator, Regulator, Battery and Starter Tester (ARBST) to test the wiper motor on the vehicle. To test the wiper motor, disconnect the windshield wiper mounting arm and pivot shaft from the windshield wiper motor; refer to Pivot Arm-Front or Pivot Arm-Rear. Disconnect the wiper motor. Connect the (1) green lead from (2) Alternator, Regulator, Battery and Starter Tester (ARBST) to the battery negative (-) post. Connect the (3) red lead from ARBST to the wiper motor (4) common brush terminal (terminal 3). Test the low speed mode by connecting a (5) cable from the battery positive (+) post to the (6) low speed brush terminal (terminal 4) and measure the current draw. If the current draw is greater than 3.5 amperes, replace the windshield wiper motor. Test the high speed mode by connecting a cable from the battery positive (+) post to the (7) high speed brush terminal (terminal 5) and measure the current draw. If the current draw is greater than 5.5 amperes, replace the wiper motor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Windshield Wiper Motor Wiper Motor: Service and Repair Windshield Wiper Motor REMOVAL CAUTION: The internal permanent magnets used in the windshield wiper motor are made of a glass-like material. To avoid damaging the magnets, do not strike the motor with a hammer or any other object. NOTE: The windshield wiper motor is not a repairable item. If worn or damaged, the motor must be replaced. 1. Remove the LH pivot arm. 1 Pull upon the pivot arm. 2 Pull out on the retainer tab and remove the pivot arm. 2. Remove the LH cowl top vent panel screw. 3. Disconnect the washer hose from the LH washer jet nozzle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Windshield Wiper Motor > Page 11399 4. Remove the LH cowl top vent panel. Release the seven spring retainers. 5. Unsnap the wiper motor clip from the RH mounting arm and pivot shaft. 6. Disconnect the RH windshield wiper mounting arm and pivot shaft from the LH windshield wiper mounting arm and pivot shaft and move both away from the windshield wiper motor. 7. Disconnect the electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Windshield Wiper Motor > Page 11400 8. Remove the ground strap nut and position the strap aside. 9. Remove the windshield wiper motor. ^ Remove the stud bolts. ^ Remove the bolts. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Windshield Wiper Motor > Page 11401 1. To install, reverse the removal procedure. CAUTION: To avoid possible damage to the mounting arm and pivot shaft retainer clip, be sure the clip is fully seated before installing on the motor crank pin. NOTE: ^ Install the LH mounting arm and pivot shaft to the motor before installing the RH mounting arm and pivot shaft. ^ Install the retainer clip on the RH mounting arm and pivot shaft prior to installing the motor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Windshield Wiper Motor > Page 11402 Wiper Motor: Service and Repair Rear Wiper Motor REMOVAL 1. Remove the rear pivot arm; refer to Pivot Arm-Rear. 2. Remove the liftgate door trim panel. 3. Position the watershield aside to gain access to the rear wiper motor. 4. Remove rear wiper motor. ^ Disconnect electrical connector. ^ Remove three retaining bolts. ^ Remove rear wiper motor. INSTALLATION 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Specifications Wiper Motor Linkage: Specifications Windshield Wiper Pivot Shaft Nut 10-13 Nm Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Specifications > Page 11406 Wiper Motor Linkage: Service Precautions CAUTION: To avoid possible damage to the windshield wiper adapter and connecting arm clip, be sure the clip is fully seated before installing the adapter and connecting arm clip on the windshield wiper motor crank pin. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Specifications > Page 11407 Wiper Motor Linkage: Service and Repair REMOVAL 1. Cycle the windshield wiper blades to the vertical position. 2. Remove the cowl top vent panels. 3. Unsnap the wiper motor clip from the RH mounting arm and pivot shaft. 4. Disconnect the RH windshield wiper mounting arm and pivot shaft from the LH windshield wiper mounting arm and pivot shaft and move both away from the windshield wiper motor. 5. Remove the RH and LH mounting arm and pivot shafts. 1 Remove the two nuts. 2 Remove the mounting arm and pivot shafts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Specifications > Page 11408 INSTALLATION 1. Install the RH and LH mounting arms and pivot shafts. 1 Position the mounting arm and pivot shafts into place. 2 Install the two nuts. 2. Install the clip onto the RH mounting arm and pivot shaft. CAUTION: To avoid possible damage to the windshield wiper adapter and connecting arm clip, be sure the clip is fully seated before installing the adapter and connecting arm clip on the windshield wiper motor crank pin. 3. Install the LH windshield wiper mounting arm and pivot shaft onto the windshield wiper motor crank pin, and install the RH windshield wiper mounting arm and pivot shaft onto the wiper motor crank pin. 4. Install the cowl top vent panels. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Timer > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Timer > Component Information > Locations > Page 11412 Wiper Motor Timer: Description and Operation Description and Operation For further information regarding this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Timer > Component Information > Locations > Page 11413 Wiper Motor Timer: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Timer > Component Information > Locations > Page 11414 Wiper Motor Timer: Service and Repair SERVICE AND REPAIR For further information regarding this component please refer to Multifunction Electronic Control Modules. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up Relay Wiper Relay: Locations Rear Wiper Up Relay Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up Relay > Page 11419 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up Relay > Page 11420 Wiper Relay: Locations Rear Wiper Down Relay Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up Relay > Page 11421 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up Relay > Page 11422 Wiper Relay: Locations Wiper High Relay Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up Relay > Page 11423 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up Relay > Page 11424 Wiper Relay: Locations Wiper Low Relay Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up Relay > Page 11425 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up Relay > Page 11426 Wiper Relay: Locations Wiper Park Relay Part (1 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper Up Relay > Page 11427 Part (2 Of 2) Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 11428 Wiper Relay: Testing and Inspection Testing an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper wires and 73 Digital Multimeter. Remove the relay to be tested from the power distribution box, fuse junction panel or individual connector. Terminals Component Testing Procedure Schematic Micro ISO Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 11429 Use the multimeter to check for the continuity between terminal 2 and all other terminals. If the resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 1 and 3 directly to the positive battery terminal. Use the multimeter set in the volts position to check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 2 and ground the jumper wire to a known good ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Rear Wiper And Washer System Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 11433 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Multifunction Switch Wiper Switch: Diagrams Multifunction Switch For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Multifunction Switch > Page 11436 Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 11437 Wiper Switch: Testing and Inspection Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 11438 Component Testing Procedure Terminals Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 11439 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 11440 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Rear Wiper Switch Wiper Switch: Service and Repair Rear Wiper Switch REMOVAL 1. Remove the instrument panel finish panel. 1 Remove the two screws. 2 Remove the center instrument panel finish panel. ^ Disconnect the electrical connectors. 2. Remove the rear wiper/washer switch. 1 Remove the screws. 2 Remove the mounting bezel. 3 Release the two tabs and remove the rear wiper/washer switch. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Rear Wiper Switch > Page 11443 1. To install, reverse the removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Rear Wiper Switch > Page 11444 Wiper Switch: Service and Repair Multifunction Switch Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position. 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove. 4. Remove the upper and lower steering column shrouds. 1 Remove the screws.